Manual Sany Mantenimiento

December 15, 2017 | Author: Juan Carlos Bermudez Cardenas | Category: Troubleshooting, Valve, Engines, Heat Pump, Mechanical Engineering
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Short Description

ESTE MANUAL ES PARA LA NUEVA GENERACION DE SANY EN SURAMERICA...

Description

www.sanygroup.com

Quailty Changes the World

Crawler Hydraulic Excavator

SY195C9 SY205C9 SY215C9

SANY HEAVY MACHINERY LIMITED

SY225C9

318A, Lianggang Avenue, Lingang Industrial Park, Fengxian District, Shanghai, P.R. of China 201413

Tel: (86) 21 5700 8518 Service hotline:(86) 4006 098 318 E-mail: [email protected] Documentation No.: ZJSYF0301EN(07-12)-SY55C3/55C9/60C1

Shop Manual

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Shop Manual

● Compiled for experienced technicians, this shop manual aims to provide technical information required for maintenance and repair of the machine. ● Work equipment or optional components not available locally may be included in this shop manual. Consult authorized Sany dealers for information on these parts and components. Material or technical specification is subject to change without prior notice.

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WARNING Read and follow the safety precautions and instructions in this manual and on the machine decals. Failure to do so may cause serious injury, death or property damage.

Table of Contents

SY195/205/215/225C9 Crawler Hydraulic Excavator

Table of Contents 1 Introduction

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1.1 How to Read the Shop Manual ................................................................................ 1-3 1.2 Terms for Maintenance Standard............................................................................. 1-5 1.3 Handling Electrical and Hydraulic Components....................................................... 1-7 1.3.1 Points to remember when handling electric components .............................. 1-7 1.3.2 Points to remember when handling hydraulic equipment ............................ 1-16 1.4 Hose Connector ..................................................................................................... 1-18 1.4.1 Type of hose connector................................................................................ 1-19 1.4.2 Hose connector tightening torque table ....................................................... 1-19 1.4.3 Connection of O-rings .................................................................................. 1-20 1.5 Table of Standard Tightening Torques .................................................................. 1-21 1.6 Type of Bolts .......................................................................................................... 1-22 1.7 Tightening Sequence ............................................................................................. 1-22 1.8 Maintenance of Half Flanges ................................................................................. 1-23 1.8.1 Table of tightening torques for half flange bolts ........................................... 1-23 1.9 Conversion Table ................................................................................................... 1-24

2 Shop Safety

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2.1 Hazard Alert Information .......................................................................................... 2-3 2.2 General Shop Safety ............................................................................................... 2-6 2.2.1 Rules and shop behavior ............................................................................... 2-7 2.2.2 Housekeeping ................................................................................................ 2-7 2.2.3 Shop Liquids Storage..................................................................................... 2-8 2.2.4 Cleaning Parts ............................................................................................... 2-8 2.2.5 Jacking Up the Machine................................................................................. 2-9 2.2.6 Electrical Dangers .......................................................................................... 2-9 2.2.7 Removing Attachments ................................................................................ 2-10 2.2.8 Cleaning the Machine .................................................................................. 2-10 2.2.9 Using the Correct Tools................................................................................ 2-10 2.2.10 Hoisting a Load ...........................................................................................2-11 2.2.11 Appropriate Working Apparel ..................................................................... 2-12 2.2.12 Safety Partners .......................................................................................... 2-12 2.2.13 Two people when engine running .............................................................. 2-13 2.2.14 Driving Pins ................................................................................................ 2-13 2.2.15 Aligning Parts or Components ................................................................... 2-14 Shop Manual - June 2013

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2.2.16 Fire Extinguisher and Emergency Exits ..................................................... 2-14 2.2.17 Personal Protective Equipment.................................................................. 2-14 2.2.18 Running the Machine ................................................................................. 2-15 2.2.19 Accumulator ............................................................................................... 2-16 2.2.20 Adding Fluids to a System ......................................................................... 2-16 2.2.21 Track Recoil Springs .................................................................................. 2-17 2.2.22 High-Pressure Fluid Lines.......................................................................... 2-17 2.2.23 Safe Work Preparations ............................................................................. 2-18 2.2.24 Mounting and Dismounting ........................................................................ 2-19 2.2.25 Battery Hazards ......................................................................................... 2-20 2.2.26 Jump-Start Safety ...................................................................................... 2-21 2.2.27 Disconnecting the System Power .............................................................. 2-21 2.2.28 Lockout/tagout ........................................................................................... 2-22 2.2.29 Sequence of Procedures ........................................................................... 2-22 2.2.30 Chemical hazard ........................................................................................ 2-24 2.2.31 Material Safety Data Sheets (MSDS) ........................................................ 2-24 2.3 Precautions for sling work and giving signals ........................................................ 2-25

3 Specifications

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Dimensions .............................................................................................................. 3-3 Working Ranges ...................................................................................................... 3-4 Technical Specifications........................................................................................... 3-5 Weight Table ............................................................................................................ 3-8 Recommended Oil, Fuel and Coolant...................................................................... 3-9 Capacity Table ....................................................................................................... 3-10 Engine Performance Curve ....................................................................................3-11

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3.1 3.2 3.3 3.4 3.5 3.6 3.7

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4 Structure and Function 4.1 Engine and Cooling System .................................................................................... 4-5 4.1.1 Engine-related parts....................................................................................... 4-5 4.1.2 Radiator and intercooler................................................................................. 4-6 4.2 Power Train.............................................................................................................. 4-7 4.2.1 Power transmission system .......................................................................... 4-7 4.2.2 Final drive assembly ...................................................................................... 4-8 4.2.3 Swing machinery...........................................................................................4-11 4.2.4 Swing bearing .............................................................................................. 4-13 4.3 Undercarriage and Frame...................................................................................... 4-14 4.3.1 Track frame and recoil spring....................................................................... 4-14 II

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4.3.2 Idler .............................................................................................................. 4-16 4.3.3 Carrier roller ................................................................................................. 4-18 4.3.4 Track roller ................................................................................................... 4-19 4.3.5 Track shoe ................................................................................................... 4-20 4.3.6 Triple grouser shoe ...................................................................................... 4-23 4.4 Hydraulic System, Part 1 ....................................................................................... 4-24 4.4.1 Hydraulic equipment layout.......................................................................... 4-24 4.4.2 Hydraulic tank and filter ............................................................................... 4-26 4.4.3 Hydraulic pump ................................................................................................... 4-27 4.4.4 Pilot pump .................................................................................................... 4-34 4.4.5 Regulator .................................................................................................... 4-35 4.4.5.1 Control mechanism makeup ............................................................... 4-37 4.4.5.2 Adjustment of the regulator ................................................................. 4-38 4.4.5.3 Operation ............................................................................................ 4-40 4.5 Hydraulic System, Part 2 ....................................................................................... 4-43 4.5.1 Control valve ................................................................................................ 4-43 4.5.2 Operating principle ....................................................................................... 4-46 4.5.2.1 When spool is in neutral position ........................................................ 4-46 4.5.2.2 Travel .................................................................................................. 4-48 4.5.2.3 Arm...................................................................................................... 4-49 4.5.2.4 Boom................................................................................................... 4-54 4.5.2.5 Bucket ................................................................................................. 4-57 4.5.2.6 Swing .................................................................................................. 4-59 4.5.2.7 Option ................................................................................................. 4-61 4.5.2.8 Travel straight ..................................................................................... 4-62 4.5.2.9 Lock valve function ............................................................................. 4-63 4.5.2.10 Main relief valve function .................................................................. 4-65 4.5.2.11 Port relief valve function .................................................................... 4-66 4.5.3 Section view ................................................................................................. 4-70 4.6 Hydraulic System, Part 3 ....................................................................................... 4-81 4.6.1 Swing motor ................................................................................................. 4-81 4.6.2 Swing holding brake..................................................................................... 4-83 4.6.3 Relief valve portion ...................................................................................... 4-84 4.6.4 Reverse prevention valve ............................................................................ 4-86 4.6.4.1 Operation drawing............................................................................... 4-86 4.6.4.2 Explanatory drawing of effects ............................................................ 4-87 4.6.5 Center swivel joint ........................................................................................ 4-89 4.6.6 Travel motor ................................................................................................. 4-91

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4.6.6.1 Operation of components.................................................................... 4-95 4.6.7 Valve control system .................................................................................. 4-107 4.6.8 Pilot valve.................................................................................................. 4-109 4.6.8.1 Work equipment and swing pilot valve.............................................. 4-109 4.6.8.2 Travel PPC valve ...............................................................................4-113 4.6.9 Solenoid valve.............................................................................................4-117 4.6.10 Accumulator ..............................................................................................4-118 4.6.11 Pilot oil filter ...............................................................................................4-119 4.6.12 Pump oil pressure sensor ........................................................................ 4-120 4.6.13 Hydraulic cylinder..................................................................................... 4-121 4.6.14 Work equipment ....................................................................................... 4-123 4.7 Air Conditioning System....................................................................................... 4-129 4.7.1 A/C components layout drawing ................................................................ 4-130 4.7.2 Control panel.............................................................................................. 4-131 4.7.3 Circuit diagram ........................................................................................... 4-132 4.7.4 Refrigeration principle ................................................................................ 4-134 4.7.4.1 Refrigeration cycle diagram .............................................................. 4-134 4.7.4.2 Heating cycle diagram ...................................................................... 4-134 4.7.5 Compressor ............................................................................................... 4-135 4.7.6 Clutch ......................................................................................................... 4-137 4.7.8 Condenser ................................................................................................. 4-138 4.7.7 Expansion valve ......................................................................................... 4-138 4.7.9 Evaporator ................................................................................................. 4-139 4.7.10 Receiver tank ........................................................................................... 4-139 4.7.11 Pressure switch ........................................................................................ 4-140 4.7.12 Fresh air sensor ....................................................................................... 4-141 4.7.13 Refrigerant ............................................................................................... 4-141 4.7.14 Compressor oil ......................................................................................... 4-160 4.8 Engine Control ..................................................................................................... 4-161 4.8.1 System operation ...................................................................................... 4-162 4.8.2 Components............................................................................................... 4-163 4.8.2.1 Fuel control dial................................................................................. 4-163 4.8.2.2 Controller .......................................................................................... 4-165 4.9 Electrical Control System..................................................................................... 4-167 4.9.1 Control function .......................................................................................... 4-167 4.9.2 Machine control system diagram ............................................................... 4-168 4.9.3 Engine and pump composite control function ............................................ 4-170 4.9.4 Pump control function ................................................................................ 4-174

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4.9.4.1 Electrical positive flow control ........................................................... 4-175 4.9.4.2 Constant power control ..................................................................... 4-178 4.9.5 Valve control function ................................................................................. 4-180 4.9.5.1 Bucket flow control ............................................................................ 4-181 4.9.5.2 Swing priority control......................................................................... 4-182 4.9.6 Duo travel speed control ............................................................................ 4-183 4.9.7 Engine preheating/overheating alarm ....................................................... 4-185 4.9.7.1 Engine preheating ............................................................................. 4-186 4.9.7.2 Engine overheating alarm ................................................................. 4-187 4.9.8 Engine oil under–pressure alarm ............................................................... 4-187 4.9.9 Auto deceleration/acceleration control ....................................................... 4-188 4.9.10 Engine speed calibration function ............................................................ 4-190 4.9.11 Electrical Components ............................................................................. 4-192 4.9.11.1 Pump pressure sensor .................................................................... 4-192 4.9.11.2 Pilot pressure sensor ...................................................................... 4-193 4.9.11.3 Engine speed sensor ...................................................................... 4-194 4.9.11.4 Coolant temperature sensor............................................................ 4-195 4.9.11.5 Fuel level sensor ............................................................................. 4-196 4.9.11.6 Oil pressure switch .......................................................................... 4-197 4.10 Monitoring System ............................................................................................. 4-198 4.10.1 Machine monitor ...................................................................................... 4-199 4.10.2 Monitor functions...................................................................................... 4-200 4.10.3 Monitor operation ..................................................................................... 4-203

5 Standard Values

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5.1 Standard Values of Engine - related Parts............................................................... 5-3 5.2 Standard Values of Chassis-related Parts ............................................................... 5-4

6 Testing and Adjusting 6.1 Engine Speed - Test and Calibrate .......................................................................... 6-3 6.1.1 Testing ........................................................................................................... 6-3 6.1.2 Adjusting ........................................................................................................ 6-3 6.2 Exhaust Gas Color - Test ......................................................................................... 6-6 6.3 Valve Clearance - Adjust.......................................................................................... 6-8 6.3.1 Testing............................................................................................................ 6-8 6.3.2 Adjusting ...................................................................................................... 6-10 6.4 Compression Pressure - Measure ..........................................................................6-11 6.5 Fuel Injection Timing - Test and Adjust .................................................................. 6-13 Shop Manual - June 2013

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6.5.1 Testing.......................................................................................................... 6-13 6.5.2 Adjusting ...................................................................................................... 6-15 6.6 Engine Oil Pressure - Measure.............................................................................. 6-17 6.7 Engine Speed Sensor - Adjust ............................................................................... 6-19 6.8 A/C Compressor Belt Tension - Test and Adjust ................................................... 6-20 6.8.1 Testing ......................................................................................................... 6-20 6.8.2 Adjusting ...................................................................................................... 6-20 6.9 Swing Bearing Clearance - Measure ..................................................................... 6-22 6.10 Track Tension - Test and Adjust ........................................................................... 6-24 6.10.1 Testing........................................................................................................ 6-24 6.10.2 Adjusting .................................................................................................... 6-25 6.11 Hydraulic Pressure in Hydraulic Circuits - Test and Adjust .................................. 6-26 6.11.1 Measuring .................................................................................................. 6-26 6.11.2 Adjusting..................................................................................................... 6-28 6.12 Control Circuit Oil Pressure - Test and Adjust...................................................... 6-30 6.12.1 Testing........................................................................................................ 6-30 6.12.2 Adjusting .................................................................................................... 6-31 6.13 Solenoid Valve Output Pressure - Measure......................................................... 6-32 6.14 Pilot Valve Output Pressure - Measure................................................................ 6-34 6.15 Pilot Valves (Work Equipment and Swing) - Adjust ............................................. 6-36 6.16 Work Equipment Hydraulic Drift - Test ................................................................. 6-37 6.17 Residual Pressure in Hydraulic Circuit - Release ................................................ 6-40 6.18 Oil Leakage - Measure ........................................................................................ 6-41 6.19 Air in Each Component - Bleed............................................................................ 6-46

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7 Troubleshooting

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7.1 Points to Remember When Troubleshooting ........................................................... 7-3 7.2 Troubleshooting Procedures .................................................................................... 7-5 7.3 Connector Location and Electrical Circuit Diagram ................................................. 7-8 7.3.1 Connector location layout ............................................................................ 7-12 7.3.2 Electrical element circuit diagram (cab circuit)............................................. 7-18 7.3.3 Electrical control circuit diagram (engine circuit).......................................... 7-20 7.3.4 Electrical control circuit diagram (sensor and solenoid valve circuit) ........... 7-22 7.3.5 SWP type connector .................................................................................... 7-23 7.3.6 A/AMP type connector ................................................................................. 7-24 7.3.7 DT type connector ....................................................................................... 7-25 7.4 Failure Symptoms and Troubleshooting Codes ..................................................... 7-26 7.5 Troubleshooting with an Event Code ..................................................................... 7-28 VI

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7.6 Troubleshooting of Electrical System (E - Mode)................................................... 7-63 7.7 Troubleshooting of Hydraulic and Mechanical Systems (H - Mode) ...................... 7-93

8 Disassembly and Assembly

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8.1 How to Read This Manual ....................................................................................... 8-5 8.1.1 Removing and Installing an Assembly ........................................................... 8-5 8.1.2 Disassembling and assembling an assembly ................................................ 8-5 8.1.3 Special tools................................................................................................... 8-5 8.2.1 The symbols used in this section .................................................................. 8-6 8.2 Operating Precautions ............................................................................................. 8-6 8.3 Start Motor AS - Remove and Install ..................................................................... 8-10 8.3.1 Removal ....................................................................................................... 8-10 8.3.2 Installation .................................................................................................... 8-10 8.4 Injection Pump AS - Remove and Install ................................................................8-11 8.4.1 Removal ........................................................................................................8-11 8.4.2 Installation .................................................................................................... 8-13 8.5 Engine Front Seal - Remove and Install ................................................................ 8-15 8.5.1 Removal ....................................................................................................... 8-15 8.5.2 Installation .................................................................................................... 8-15 8.6 Engine Rear Seal - Remove and Install................................................................. 8-16 8.6.1 Removal ....................................................................................................... 8-16 8.6.2 Installation .................................................................................................... 8-17 8.7 Cylinder Head AS - Remove and Install ................................................................ 8-18 8.7.1 Removal ....................................................................................................... 8-18 8.7.2 Installation .................................................................................................... 8-22 8.8 Radiator AS - Remove and Install.......................................................................... 8-24 8.8.1 Removal ....................................................................................................... 8-24 8.8.2 Installation .................................................................................................... 8-27 8.9 Engine and Hydraulic Pump AS - Remove and Install .......................................... 8-28 8.9.1 Removal ....................................................................................................... 8-28 8.9.2 Installation .................................................................................................... 8-34 8.10 Final Drive AS - Remove and Install .................................................................... 8-35 8.10.1 Removal ..................................................................................................... 8-35 8.10.2 Installation .................................................................................................. 8-36 8.11 Final Drive AS - Disassemble and Assemble ....................................................... 8-37 8.11.1 Disassembly ............................................................................................... 8-37 8.11.2 Assembly .................................................................................................... 8-41 8.12 Swing Motor and Swing Drive AS - Remove and Install ...................................... 8-46 Shop Manual - June 2013

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8.12.1 Removal ..................................................................................................... 8-46 8.12.2 Installation .................................................................................................. 8-47 8.13 Swing Motor and Swing Drive AS - Disassemble and Assemble......................... 8-48 8.13.1 Disassembly............................................................................................... 8-48 8.13.2 Assembly.................................................................................................... 8-53 8.14 Idler AS - Disassemble and Assemble ................................................................. 8-58 8.14.1 Disassembly............................................................................................... 8-58 8.14.2 Assembly.................................................................................................... 8-59 8.15 Sprocket - Remove and Install............................................................................. 8-62 8.15.1 Removal ..................................................................................................... 8-62 8.15.2 Installation .................................................................................................. 8-62 8.16 Track AS - Remove and Install ............................................................................ 8-63 8.16.1 Removal ..................................................................................................... 8-63 8.16.2 Installation .................................................................................................. 8-65 8.17 Swing Bearing AS - Remove and Install .............................................................. 8-66 8.17.1 Removal ..................................................................................................... 8-66 8.17.2 Installation .................................................................................................. 8-67 8.18 Swing Platform AS - Remove and Install ............................................................. 8-68 8.18.1 Removal ..................................................................................................... 8-68 8.18.2 Installation .................................................................................................. 8-71 8.19 Swivel Joint AS - Remove and Install .................................................................. 8-72 8.19.1 Removal ..................................................................................................... 8-72 8.19.2 Installation .................................................................................................. 8-74 8.20 Swivel Joint AS - Disassemble and Assemble ..................................................... 8-75 8.20.1 Disassembly............................................................................................... 8-75 8.20.2 Assembly.................................................................................................... 8-76 8.21 Hydraulic Tank AS - Remove and Install.............................................................. 8-77 8.21.1 Removal ..................................................................................................... 8-77 8.21.2 Installation .................................................................................................. 8-79 8.22 Control Valve AS - Remove and Install ................................................................ 8-80 8.22.1 Removal ..................................................................................................... 8-80 8.22.2 Installation .................................................................................................. 8-84 8.23 Hydraulic Pump AS - Remove and Install ............................................................ 8-85 8.23.1 Removal ..................................................................................................... 8-85 8.23.2 Installation .................................................................................................. 8-89 8.24 Middle Oil Seal (Hydraulic Pump Input Shaft)- Remove and Install .................... 8-90 8.24.1 Removal ..................................................................................................... 8-90 8.24.2 Installation .................................................................................................. 8-90

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8.25 Pilot Valve AS (Work Equipment) - Disassemble and Assemble ......................... 8-91 8.25.1 Assembly.................................................................................................... 8-91 8.26 Pilot Valve AS (Travel) - Disassemble and Assemble .......................................... 8-93 8.26.1 Assembly.................................................................................................... 8-93 8.27 Hydraulic Cylinder AS - Disassemble and Assemble........................................... 8-94 8.27.1 Disassembly............................................................................................... 8-95 8.27.2 Assembly.................................................................................................. 8-100 8.28 Work Equipment AS - Remove and Install......................................................... 8-105 8.28.1 Removal ................................................................................................... 8-105 8.28.2 Installation ................................................................................................ 8-107 8.29 Air Conditioner AS - Remove and Install............................................................ 8-108 8.29.1 Removal ................................................................................................... 8-108 8.29.2 Installation .................................................................................................8-112 8.30 Counterweight AS - Remove and Install .............................................................8-113 8.30.1 Removal ....................................................................................................8-113 8.30.2 Installation .................................................................................................8-114 8.31 Cab AS - Remove and Install..............................................................................8-115 8.31.1 Removal ....................................................................................................8-115 8.31.2 Installation .................................................................................................8-119 8.32 Cab Window Glass – Disassemble and Assemble ............................................ 8-120 8.32.1 Removal ................................................................................................... 8-121 8.32.2 Installation ................................................................................................ 8-125 8.33 Front Window AS - Disassemble and Assemble................................................ 8-138 8.33.1 Disassemble ............................................................................................ 8-138 8.33.2 Assemble ................................................................................................. 8-141 8.34 Monitor - Remove and Install ............................................................................. 8-146 8.34.1 Removal ................................................................................................... 8-146 8.34.2 Installation ................................................................................................ 8-146 8.35 Controller AS - Remove and Install.................................................................... 8-147 8.35.1 Removal ................................................................................................... 8-147 8.35.2 Installation ................................................................................................ 8-147 8.36 Radio ................................................................................................................. 8-148 8.36.1 Structure .................................................................................................. 8-148 8.36.2 Removal ................................................................................................... 8-149 8.36.3 Installation ................................................................................................ 8-150 8.36.4 Connector model and wiring .................................................................... 8-150 8.37 Battery ............................................................................................................... 8-151 8.37.1 Structure .................................................................................................. 8-151

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8.37.2 Removal ................................................................................................... 8-152 8.37.3 Installation ................................................................................................ 8-153 8.37.4 Replacement ............................................................................................ 8-153 8.38 Start Switch........................................................................................................ 8-154 8.38.1 Structure ................................................................................................. 8-154 8.38.2 Removal ................................................................................................... 8-155 8.39 Fuse Box............................................................................................................ 8-157 8.39.1 Removal ................................................................................................... 8-157 8.40 Wiper ................................................................................................................. 8-158 8.40.1 Structure .................................................................................................. 8-158 8.40.2 Working principle ..................................................................................... 8-158 8.40.3 Removal ................................................................................................... 8-159 8.40.5 Installation ................................................................................................ 8-160 8.40.4 Angle adjustment of wiper arm................................................................. 8-160 8.41 Relay.................................................................................................................. 8-161 8.41.1 Engine relays ........................................................................................... 8-161 8.41.2 Other relays ............................................................................................. 8-162 8.42 Sensor ............................................................................................................... 8-165 8.43 Connector Terminals - Insert and Remove ........................................................ 8-167 8.43.1 Insertion ................................................................................................... 8-167 8.43.2 Removal ................................................................................................... 8-168

9 System Schematics

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Hydraulic System Diagram ...................................................................................... 9-3 Air-Conditioning Electrical Circuit Diagram .............................................................. 9-4 Fuse Box Relay ....................................................................................................... 9-5 Control Switches and Monitor Electrical Diagram ................................................... 9-6 Operator Cab Electrical Circuit Diagram.................................................................. 9-7 Chassis Electrical Circuit Diagram........................................................................... 9-8

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9.1 9.2 9.3 9.4 9.5 9.6

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Introduction

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1 Introduction

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1.1 How to Read the Shop Manual ................................................................................ 1-3 1.2 Terms for Maintenance Standard............................................................................. 1-5 1.3 Handling Electrical and Hydraulic Components....................................................... 1-7 1.3.1 Points to remember when handling electric components .............................. 1-7 1.3.2 Points to remember when handling hydraulic equipment ............................ 1-16 1.4 Hose Connector ..................................................................................................... 1-18 1.4.1 Type of hose connector................................................................................ 1-19 1.4.2 Hose connector tightening torque table ....................................................... 1-19 1.4.3 Connection of O-rings .................................................................................. 1-20 1.5 Table of Standard Tightening Torques .................................................................. 1-21 1.6 Type of Bolts .......................................................................................................... 1-22 1.7 Tightening Sequence ............................................................................................. 1-22 1.8 Maintenance of Half Flanges ................................................................................. 1-23 1.8.1 Table of tightening torques for half flange bolts ........................................... 1-23 1.9 Conversion Table ................................................................................................... 1-24

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Introduction

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1-2

WARNING

Read and understand all safety precautions and instructions in this manual before reading any other manuals provided with this machine and before operating or servicing the machine. Also read the safety information on machine decals before performing any operations. Failure to do so can cause machine damage, personal injury or death.

Shop Manual - June 2013

Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

1 INTRODUCTION 1.1 How to Read the Shop Manual 1. Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.

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Introduction

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This section provides an overview of what is covered in the rest of this manual and how to use this manual,. Shop Safety

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This section covers basic shop safety information relating to this equipment. It also describes what the hazard alerts mean that are used throughout the manual. Specifications

Technical specification of work equipment and optional parts are given in this section.

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Structure and function

Standard Values

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This section explains the structure and function of each component. It helps the reader to get a better understanding of the machine structure, and also serves as a reference for troubleshooting.

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This section explains the standard values for a new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. Testing and adjusting

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This section details the inspection before and after repair work as well as the adjustment during inspection and repair work. Troubleshooting table that involves “Fault”and “Cause”are also included in this section. Troubleshooting This section explains the way to detect faulty parts and the method to repair them. This section is divided into the following parts: Electrical system, Engine, Hydraulic and mechanical system and Monitoring system. Disassembly and assembly This section explains the procedures as well as precautions for removing, installing, disassembling and assembling of each component.

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Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

System Schematics This section provides hydraulic circuit diagrams and electrical circuit diagrams. 2. Revision and distribution

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Any additions, revisions, or other change of notices will be sent to Sany distributors. Get the most up-to-date information before you start any work.

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3. Units

In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.

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4. Symbols

Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Item

Remarks

Safety

Special technical precautions or other precautions for preserving standards are necessary when performing work.

Weight

Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc.

Tightening torque

Places that require special attention for tightening torque during assembly.

Coat

Places to be coated with adhesives, etc. during assembly.

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Oil, Coolant Drain

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Special safety precautions are necessary when performing work.

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Symbol

Places where oil, etc. must be added, and capacity. Places where oil, etc. must be drained, and quantity to be drained.

Shop Manual - June 2013

Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

1.2 Terms for Maintenance Standard The maintenance standard values necessary for judgment of products and parts are described by the following terms. 1. Standard size and tolerance

RI C

A

● To be accurate, the finishing size of parts is a little different from one to another.

● The above size set temporarily is called the "standard size" and the range of difference from the standard size is called the "tolerance".

TI N

● The tolerance with the symbols of + or – is indicated on the right side of the standard size.

120

Tolerance

LA

Example Standard size

AM E

● To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated.

–0.022 –0.126

SA

NY

NOTE: The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (–0.022/–0.126) ● Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance.

Std.size F 60 Tolerance of hole (upper):+0.046 Std.clearance (max.):0.122 Std.clearance (min.):0.030 Tolerance of shaft (lower):-0.076 Tolerance of shaft (upper):-0.030

● Indication of size of rotating shaft and hole and relationship drawing of them. ZX215-1000003

Shop Manual - June 2013

1-5

Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

4. Repair limit and allowable value

φ60

Hole +0.046 0

2. Standard clearance and standard value ● The clearance made when new parts are assembled is called the "standard clearance", which is indicated by the range from the minimum clearance to the maximum clearance. ● When some parts are repaired, the clearance is generally adjusted to the standard clearance.

● The performance and function of a product lowers while it is used. A value below which the product can be used without causing a problem is called the "allowable value". ● If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement. 5. Clearance limit

TI N

● A value of performance and function of new products or equivalent is called the "standard value", which is indicated by a range or a target value.

● If a part is worn to the repair limit must be replaced or repaired.

A

Shaft -0.030 -0.076

● The size of a part changes due to wear and deformation while it is used. The limit of changed size is called the "repair limit".

RI C

Tolerance

Standard size

AM E

Example

3. Standard interference

LA

● When some parts are repaired, the value of performance/function is set to the standard value.

NY

● When the size of a hole is smaller than the size of a shaft because of the standard size and tolerance, the difference between these sizes is called the "interference".

SA

● The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the shaft to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the "standard interference". ● After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range.

1-6

● Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the "clearance limit". ● If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired.

6. Interference limit ● The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the "interference limit". ● The interference limit shows the repair limit of the part of smaller tolerance. ● If the interference between the parts exceeds the interference limit, they must be replaced or repaired.

Shop Manual - June 2013

Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

1.3 Handling Electrical and Hydraulic Components

AM E

RI C

A

To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct "operation", "maintenance and inspection", "troubleshooting", and "repairs" must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on "Handling electric components" and "Handling hydraulic equipment" (particularly gear oil and hydraulic oil).

1.3.1 Points to remember when handling electric components 1. Handling wiring harnesses and connectors

LA

TI N

Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring.

ZX215-1000004

SA

NY

Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses.

Shop Manual - June 2013

1-7

Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

2. Main failures occurring in wiring harness 1) Defective contact of connectors (defective contact between male and female) Improper insertion

RI C

A

Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidation of the contact surfaces.

2) Defective crimping or soldering of connectors

3) Disconnections in wiring

LA

TI N

The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.

AM E

ZX215-1000005

Crimped portion

ZX215-1000006

SA

NY

If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.

ZX215-1000007

1-8

Shop Manual - June 2013

Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

RI C

ZX215-1000008

AM E

The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. Accordingly, take care not splash water over the connector. The connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be shortcircuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it.

A

4) High-pressure water entering connector

TI N

5) Oil or dirt stuck to connector

NOTE:

NY

LA

If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer.

ZX215-1000009

SA

● When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. ● If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.

Shop Manual - June 2013

1-9

Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

3. Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors a. Hold the connectors when disconnecting.

b. When removing from clips

A ZX215-1000010

Both stoppers

ZX215-1000011

NY

LA

TI N

● Both of the connector and clip have stoppers, which are engaged with each other when the connector is installed.

RI C

NOTE: Never pull with one hand.

Lock stopper

AM E

When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart.

Press lightly when removing

SA

● When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers.

ZX215-1000012

1-10

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Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

c. Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion.

RI C

A

NOTE: If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.

a. Check the connector visually Check that there is no oil, dirt, or water stuck to the connector pins (mating portion).

AM E

2) Connecting connectors

ZX215-1000013

Clicks into position

TI N

Check that there is no deformation, defective contact, corrosion, or damage to the connector pins.

ZX215-1000022

LA

Check that there is no damage or breakage to the outside of the connector.

SA

NY

NOTE: If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. NOTE: If there is any damage or breakage, replace the connector.

Shop Manual - June 2013

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Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

b. Fix the connector securely. Align the position of the connector correctly, and then insert it securely. For connectors with lock stopper, push in the connector until the stopper clicks into position.

A

c. Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position.

RI C

ZX215-1000014

AM E

NOTE: If the connector cannot be corrected easily, remove the clamp and adjust the position.

LA

TI N

● If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.

ZX215-1000015

3) Connecting DT connectors

2

a

1

c

NY

Since the DT 8-pin and 12-pin heavy duty wire connectors have 2 latches respectively, push them in until they click 2 times.

SA

● Male connector: 1

● Female connector: 2 ● Normal locking state (Horizontal): a, b, d

b

d ZX215-1000016

● Incomplete locking state (Diagonal): c

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Shop Manual - June 2013

Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

4) Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows.

b. Dry the connector with a dryer.

RI C

ZX215-1000009

AM E

NOTE: If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from the compressed air before blowing with air.

A

a. Disconnect the connector and wipe off the water with a dry cloth.

TI N

If water gets inside the connector, use a dryer to dry the connector.

ZX215-1000017

LA

NOTE: Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.

NY

c. Carry out a continuity test on the connector.

SA

After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. NOTE: After completely drying the connector, blow it with contact restorer and reassemble.

Shop Manual - June 2013

T adapter

ZX215-1000018

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Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

4. Handling the integrated control monitor

A

1) The controller contains a microcomputer and an electronic control circuits. They control all of the electronic circuits on the machine, so be extremely careful when handling the integrated control monitor.

RI C

2) Do not place objects on the controller. 3) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand.

6) Precautions for arc welding

TI N

5) Do not place the controller on oil, water, or soil, or in any hot place, even for a short time.

AM E

4) Do not leave it where it may be exposed to rain.

ZX215-1000019

ZX215-1000020

SA

NY

LA

When welding on the controller, disconnect all wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.

Tool Box

ZX215-1000021

1-14

Shop Manual - June 2013

Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

5. Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connecting connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.

RI C

A

NOTE: Disconnect and connect the related connectors several times to check.

NOTE: If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated.

TI N

4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester.

AM E

3) Always connect any disconnected connectors before going on to the next step.

SA

NY

LA

NOTE: If there is any change, there is probably defective contact in that circuit.

Shop Manual - June 2013

1-15

Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

1.3.2 Points to remember when handling hydraulic equipment

RI C

A

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.

Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust. 2. Disassembly and maintenance work in the field

ZX215-1000023

NY

LA

TI N

If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to check the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dust-proof workshop, and the performance should be checked with special test equipment.

AM E

1. Be careful of the operating environment

SA

3. Sealing openings

After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out onto the ground, but collect it and ask the customer to dispose of it, or take it back with you for disposal.

1-16

Shop Manual - June 2013

ZX215-1000024

Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

4. Do not let any dirt or dust get in during refilling operations

RI C

A

Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.

LA

TI N

When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil.

ZX215-1000025

AM E

5. Change hydraulic oil when the temperature is high

NY

6. Flushing operations

Flushing oil

SA

After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.

ZX215-1000026

Shop Manual - June 2013

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Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

7. Cleaning operations

A

After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultra fine (about 3 μ) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.

1.4 Hose Connector

TI N

Hose connector is used to connect hoses with a small diameter. The metal sealing surface (4) of the joint (1) must be in close contact with the metal sealing surface (5) of the hose (2) to seal pressurized oil.

AM E

RI C

ZX215-1000027

NOTICE

NY

LA

● Do not over-tighten the nut (3). Excessive force applied on the metal sealing surface (4) and (5) may cause the joint (1) to break. Be sure to tighten nut (3) according to technical specifications.

SA

● Scratches or other damages on sealing surface (4) and (5) may cause leaks at the joint. Be extremely careful not to damage the sealing surfaces during connecting and disconnecting work.

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Shop Manual - June 2013

1

4

3

5

2

Connector ZX215-1000028

Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

1.4.1 Type of hose connector 24° 24°

Female

A

Male

RI C

ZX215-1000029

Type

Wrench size mm

Wrench size mm

Connecting nut

AM E

1.4.2 Hose connector tightening torque table

Hose joint

N·m(kgf·m,Ibf·ft)

19

59(6,44)

22

98(10,72)

27

118(12,87)

36

235(24,173)

41

41

295(30,218)

50

50

490(50,361)

60

60

670(68,494)

70

70

980(100,723)

19

17

44(4.5,32)

22

19

59(6,44)

27

22

118(12,87)

36

30, 32

235(24,173)

41

36

295(30,218)

50

46

490(50,361)

19 22 27 36

LA

TI N

24° Male

SA

NY

24° Female

Tightening torque

NOTICE

● The torque values listed in the table are intended for general application. ● Do not use torque values listed in this table when different torque values are specified for a special purpose.

Shop Manual - June 2013

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Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

1.4.3 Connection of O-rings Place O-ring (6) in contact with the contact surface of the joint (7) to seal the pressurized oil.

7

6

9

NOTICE

A

● Replace o-rings (6) with new ones when re-connecting hoses.

Hose connector

RI C 8

● Before tightening nut (9), make sure the o-ring (6) has been placed into the o-ring seat (8).Displacement of the o-ring may have it damaged and cause leaks.

10

AM E

ZX215-1000030

● Be careful not to damage the o-ring seat (8) or the sealing surface (10). Damaged o-ring (6) may cause oil leakage.

Wrench size mm

LA

TI N

● If oil leakage due to loosened nut (9) is detected, do not try to stop the leakage by tightening nut (9). Instead, replace oring (6) with a new one and make sure it is well positioned, and tighten nut (9).

Wrench size mm

Tightening torque

Hose joint

N·m (kgf·m,Ibf·ft)

19

17

44(4.5,32)

22

19

59(6,44)

27

22

118(12,87)

36

30, 32

235(24,173)

41

36

295(30,218)

50

46

490(50,361)

SA

NY

Connecting nut

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Shop Manual - June 2013

Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

1.5 Table of Standard Tightening Torques Table of tightening torques for bolts and nuts ● Unless specified otherwise, tighten metric nuts and bolts to the torque below. (When using torque wrench)

Bolt diameter

Bolt grade

Wrench Hex wrench size size

M6

10.9

10

M8

10.9

M10

Hexagonal bolt

Hexagonal socket head bolt

kgf·m

lbf·ft

N·m

4

13.2

1.37

9.74

13.2

13

6

31

3.16

22.87

31

3.16

22.87

10.9

17

8

66

6.73

48.7

66

6.73

48.7

M12

10.9

19

10

113

11.53

83.39

113

11.53

83.39

M14

10.9

22

12

177

18.06

130.6

177

18.06

130.6

M16

10.9

24

14

279

28.47

205.9

279

28.47

205.9

M18

10.9

27

14

382

38.98

281.9

382

38.98

281.9

M20

10.9

30

17

549

56.02

405.16

549

56.02

405.16

M27

10.9

41

19

1320

134.7

974.16

1320

134.7

974.16

M10

12.9

17

6

78

7.96

57.76

78

7.96

57.76

M12

12.9

19

8

137

13.98

101.1

137

13.98

101.1

M16

12.9

24

14

339

34.6

250.18

339

34.6

250.18

M20

12.9

30

17

664

67.75

490

664

67.75

490

lbf·ft

1.37

9.74

RI C

AM E

TI N

LA

kgf·m

A

N·m

NOTICE

The following items apply to fine thread and coarse thread.

NY

● Apply grease (zinc white B dissolved in spindle oil) onto the nuts and bolts to reduce the friction coefficient. Thrust bolts do not require greasing.

SA

● Torque tolerance is ±10%. ● Always use bolts of correct length. The tip of bolts with excessive length may contact the bottom of the bolt hole, resulting in under-tightening. Bolts with inadequate length may result in insufficient fastening. ● The torque values listed in the table are intended for general application. If different torque values are specified for a special purpose, the torque values in this table are not applicable any more. ● Make sure the threads are free of dirt or rusts before installation of nuts and bolts.

Shop Manual - June 2013

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Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

1.6 Type of Bolts Tighten nuts and bolts properly to specified torque values. The type and grade of bolts are illustrated on the right. Hex bolt

Use correct bolts and tighten them properly when assembling machines or components.

12.9

10.9

RI C

A

8.8

Socket head hex bolt

ZX215-1000031

When two or more bolts are being tightened, follow the tightening sequence shown on the right to ensure even tightening.

AM E

1.7 Tightening Sequence

Cross tightening

Diagonal tightening 1

1

3

3

6

4

5

4

CAUTION

TI N

2

● Always use suitable tools for specific work. Use of improper tools and methods may cause a hazardous situation.

Central and diagonal tightening 12

9

4

1

6

7

14

13

8

5

2

3

10

11

ZX215-1000032

SA

NY

LA

● Use tools of correct sizes when loosening or tightening the nuts or bolts. Otherwise, the tools may slide and cause personal injury.

2

ZX215-1000033

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Shop Manual - June 2013

Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

1.8 Maintenance of Half Flanges

A

1. Clean the sealing surface of the flange and check it carefully. Scratches and coarseness cause leaks or abrasion of seals. Uneven surface may squeeze the seal out. If these faults are not corrected properly, parts may have to be replaced.

AM E

ZX215-1000034

Improper

LA

TI N

3. Tighten the half flanges carefully. Locate the opening at the center so that it is perpendicular to the oil opening. Tighten the bolt manually to maintain the location of the components.

RI C

2. Always use specified O-rings. Check that the O-rings are not damaged. Do not file the surface of the O-ring. Apply grease onto the O-ring to locate it.

ZX215-1000035

1.8.1 Table of tightening torques for half flange bolts

NY

● Unless specified otherwise, tighten the half flange bolts to the torques below.

SA

Thread diameter of bolt

Width across flats

Tightening torque

mm

mm

Nm

kgm

10 12 16

14 17 22

59~74 98~123 235~285

6.0~7.5 10.0~12.5 23.5~29.5

Shop Manual - June 2013

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Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

1.9 Conversion Table The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below. Example: Method of using the conversion table to convert from millimeters to inches 1. Convert 55 mm into inches

RI C

A

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A). 2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B).

AM E

3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 550 mm into inches

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the left) to convert it to 55 mm.

TI N

2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.

SA

NY

LA

3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

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Shop Manual - June 2013

Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

Length Millimeters to Inches 1mm=0.03937in

(B) 2

3

4

5

6

7

8

9

0 10 20 30 40

0.000 0.394 0.787 1.181 1.575

0.039 0.433 0.827 1.220 1.614

0.079 0.472 0.866 1.260 1.654

0.118 0.512 0.906 1.299 1.693

0.157 0.551 0.945 1.339 1.732

0.197 0.591 0.984 1.378 1.772 (C)

0.236 0.630 1.024 1.417 1.811

0.276 0.669 1.063 1.457 1.850

0.315 0.709 1.102 1.496 1.890

0.354 0.748 1.142 1.535 1.929

50 60 70 80 90

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

2.165 2.559 2.953 3.346 3.740

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.031 3.425 3.819

2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

1

2

0 10 20 30 40

0 0.394 0.787 1.181 1.575

0.039 0.433 0.827 1.220 1.614

0.079 0.472 0.866 1.260 1.654

50 60 70 80 90

1.969 2.362 2.756 3.150 3.543

NY

SA

2.008 2.402 2.795 3.189 3.583

2.047 2.441 2.835 3.228 3.622

RI C

1mm=0.03937in

3

4

5

6

7

8

9

0.118 0.512 0.906 1.299 1.693

0.157 0.551 0.945 1.339 1.732

0.197 0.591 0.984 1.378 1.772

0.236 0.630 1.024 1.417 1.811

0.276 0.669 1.063 1.457 1.850

0.315 0.709 1.102 1.496 1.890

0.354 0.748 1.142 1.535 1.929

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

2.165 2.559 2.953 3.346 3.740

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.031 3.425 3.819

2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

LA

0

TI N

Millimeters to Inches

A

1

AM E

(A)

0

Shop Manual - June 2013

1-25

Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

Inches to Millimeters mm

1/32 1/16 3/32 1/8

19/32

3.5719

3/16

4.3656 4.7625

13/64

41/64

5.5563 15/64

1/4 9/32

23/64

9.1281

13/32

10.3188

25/64 27/64

7/16

9.5250

15/32

51/64

7/8 29/32

19.4469 20.2406 21.0344 21.8281 22.6219 23.0188

59/64 15/16

23.4156 23.8125

11.5094

61/64 31/32

24.2094 24.6063

63/64

Shop Manual - June 2013

18.6531

22.2250 57/64

1

17.8594

21.4313 55/64

10.7156

12.7000

17.0656

20.6375 27/32

12.3031

16.6688

19.8438

53/64

11.9063 31/64

25/32

9.9219

11.1125 29/64

49/64

13/16

8.7313

16.2719

19.0500

8.3344

NY

11/32

15.8750

18.2563

3/4

7.5406

LA

21/64

45/64 47/64

6.7469

7.9375

15.4781

17.4625

23/32

7.1438

19/64

43/64

11/16

5.9531

6.3500

17/64

21/32

TI N

7/32

5.1594

14.6844 15.0813

39/64

3.9688 11/64

SA

37/64

5/8

13.8906 14.2875

AM E

5/32

1-26

9/16

2.7781

13.0969 13.4938

35/64

1.9844

3.1750 9/64

1/2

17/32

2.3813 7/64

5/16

33/64

1.1906 1.5875

5/64

3/8

0.3969 0.7938

3/64

mm

A

1/64

in.

RI C

in.

25.0031 25.4000

Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

Feet to Meters 0

1

2

3

4

5

6

7

8

9

ft.

m

m

m

m

m

m

m

m

m

m

-

-

0.305

0.610

0.914

1.219

1.524

1.829

2.134

2.438

2.743

-

10

3.048

3.353

3.658

3.962

4.267

4.572

4.877

5.182

5.486

5.791

10

20

6.096

6.401

6.706

7.010

7.315

7.620

7.925

8.230

8.534

8.839

20

30

9.144

9.449

9.754

10.058 10.363 10.668 10.973 11.278 11.582 11.887

30

40

12.192 12.497 12.802 13.106 13.411 13.716 14.021 14.326 14.630 14.935

50

15.240 15.545 15.850 16.154 16.459 16.764 17.069 17.374 17.678 17.983

50

60

18.288 18.593 18.898 19.202 19.507 19.812 20.117 20.422 20.726 21.031

60

70

21.336 21.641 21.946 22.250 22.555 22.860 23.165 23.470 23.774 24.079

70

80

24.384 24.689 24.994 25.298 25.603 25.908 26.213 26.518 26.822 27.127

80

90

27.432 27.737 28.042 28.346 28.651 28.956 29.261 29.566 29.870 30.175

90

100

30.480 30.785 31.090 31.394 31.699 32.004 32.309 32.614 32.918 33.223

100

AM E

RI C

A

ft.

40

m

1

2

ft.

ft.

ft.

-

3.2808

6.5617

3

4

5

6

7

8

9

ft.

ft.

ft.

ft.

ft.

ft.

ft.

9.8425

13.1234 16.4042 19.6850 22.9659 26.2467 29.5276

m

-

LA

-

0

TI N

Meters to Feet

10 32.8084 36.0892 39.3701 42.6509 45.9318 49.2126 52.4934 55.7743 59.0551 62.3360 10 20 65.6168 68.8976 72.1785 75.4593 78.7402 82.0210 85.3018 88.5827 91.8635 95.1444 20 30 98.4252 101.7060 104.9869 108.2677 111.5486 114.8294 118.1102 121.3911 124.6719 127.9528 30

NY

40 131.2336 134.5144 137.7953 141.0761 144.3570 147.6378 150.9186 154.1995 157.4803 160.7612 40 50 164.0420 167.3228 170.6037 173.8845 177.1654 180.4462 183.7270 187.0079 190.2887 193.5696 50

SA

60 196.8504 200.1312 203.4121 206.6929 209.9738 213.2546 216.5354 219.8163 223.0971 226.3780 60 70 229.6588 232.9396 236.2205 239.5013 242.7822 246.0630 249.3438 252.6247 255.9055 259.1864 70 80 262.4672 265.7480 269.0289 272.3097 275.5906 278.8714 282.1522 285.4331 288.7139 291.9948 80 90 295.2756 298.5564 301.8373 305.1181 308.3990 311.6798 314.9606 318.2415 321.5223 324.8032 90 100 328.0840 331.3648 334.6457 337.9265 341.2074 344.4882 347.7690 351.0499 354.3307 357.6116 100

Shop Manual - June 2013

1-27

Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

Miles to Kilometers 1

2

3

4

5

6

7

8

9

km

km

km

km

km

km

km

km

km

km

-

-

1.609

3.219

4.828

6.437

8.047

9.656

11.265

12.875

14.484

-

10

16.093

17.703

19.312

20.921

22.531

24.140

25.749

27.359

28.968

30.577

10

20

32.187

33.796

35.405

37.015

38.624

40.234

41.843

43.452

45.062

46.671

20

30

48.280

49.890

51.499

53.108

54.718

56.327

57.936

59.546

61.155

62.764

30

40

64.374

65.983

67.592

69.202

70.811

72.420

74.030

75.639

77.248

50

80.467

82.077

83.686

85.295

86.904

88.514

90.123

91.732

94.951

50

60

96.561

98.170

99.779 101.388 102.998 104.607 106.216 107.826 109.435 111.044

60

70

112.654 114.263 115.872 117.482 119.091 120.701 122.310 123.919 125.529 127.138

70

80

128.748 130.357 131.966 133.575 135.185 136.794 138.403 140.013 141.622 143.231

80

90

144.841 146.450 148.059 149.669 151.278 152.887 154.497 156.106 157.715 159.325

A

0

RI C

78.858

93.342

AM E

miles

miles

40

90

100 160.934 162.543 164.153 165.762 167.371 168.981 170.590 172.199 173.809 175.418 100

0

1

2

3

5

6

7

8

9

miles

miles

miles

miles

miles

miles

miles

miles

miles

miles

-

-

0.621

1.243

1.864

2.485

3.107

3.728

4.350

4.971

5.592

-

10

6.214

6.835

7.456

8.078

8.699

9.321

9.942

10.563

11.185

11.806

10

20

12.427

13.049

13.670

14.292

14.913

15.534

16.156

16.777

17.398

18.020

20

30

18.641

19.262

19.884

20.505

21.127

21.748

22.369

22.991

23.612

24.233

30

40

24.855

25.476

26.098

26.719

27.340

27.962

28.583

29.204

29.826

30.447

40

50

31.069

31.690

32.311

32.933

33.554

34.175

34.797

35.418

36.039

36.661

50

60

37.282

37.904

38.525

39.146

39.768

40.389

41.010

41.632

42.253

42.875

60

70

43.496

44.117

44.739

45.360

45.981

46.603

47.224

47.845

48.467

49.088

70

80

49.710

50.331

50.952

51.574

52.195

52.816

53.438

54.059

54.681

55.302

80

90

55.923

56.545

57.166

57.787

58.409

59.030

59.652

60.273

60.894

61.516

90

100

62.137

62.758

63.380

64.001

64.622

65.244

65.865

66.487

67.108

67.729

100

1-28

NY

LA

4

SA

km

TI N

Kilometers to Miles

Shop Manual - June 2013

km

Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

Area Square inches to square centimeters in2

in2

1

2

3

4

5

6

7

8

9

cm2

cm2

cm2

cm2

cm2

cm2

cm2

cm2

cm2

cm2

-

-

6.452

12.903

19.355

25.806

32.258

38.710

45.161

51.613

58.064

10

64.516

70.968

77.419

83.871

90.322

96.774 103.226 109.677 116.129 122.580

10

20

129.032 135.484 141.935 148.387 154.838 161.290 167.742 174.193 180.645 187.096

20

30

193.548 200.000 206.451 212.903 219.354 225.806 232.258 238.709 245.161 251.612

30

40

258.064 264.516 270.967 277.419 283.870 290.322 296.774 303.225 309.677 316.128

40

50

322.580 329.032 335.483 341.935 348.386 354.838 361.290 367.741 374.193 380.644

50

60

387.096 393.548 399.999 406.451 412.902 419.354 425.806 432.257 438.709 445.160

60

70

451.612 458.064 464.515 470.967 477.418 483.870 490.322 496.773 503.225 509.676

70

80

516.128 522.580 529.031 535.483 541.934 548.386 554.838 561.289 567.741 574.192

80

90

580.644 587.096 593.547 599.999 606.450 612.902 619.354 625.805 632.257 638.708

90

AM E

RI C

A

0

-

100 645.160 651.612 658.063 664.515 670.966 677.418 683.870 690.321 696.773 703.224 100

1

2

4

5

6

7

8

9

in2

in2

in2

in2

in2

in2

in2

in2

in2

in2

-

-

0.155

0.310

0.465

0.620

0.775

0.930

1.085

1.240

1.395

-

10

1.550

1.705

1.860

2.015

2.170

2.325

2.480

2.635

2.790

2.945

10

20

3.100

3.255

3.410

3.565

3.720

3.875

4.030

4.185

4.340

4.495

20

30

4.650

4.805

4.960

5.115

5.270

5.425

5.580

5.735

5.890

6.045

30

40

6.200

6.355

6.510

6.665

6.820

6.975

7.130

7.285

7.440

7.595

40

50

7.750

7.905

8.060

8.215

8.370

8.525

8.680

8.835

8.990

9.145

50

60

9.300

9.455

9.610

9.765

9.920

10.075

10.230

10.385

10.540

10.695

60

70

10.850

11.005

11.160

11.315

11.470

11.625

11.780

11.935

12.090

12.245

70

80

12.400

12.555

12.710

12.865

13.020

13.175

13.330

13.485

13.640

13.795

80

90

13.950

14.105

14.260

14.415

14.570

14.725

14.880

15.035

15.190

15.345

90

100

15.500

15.655

15.810

15.965

16.120

16.275

16.430

16.585

16.740

16.895

100

SA

NY

0

cm2

3

LA

cm2

TI N

Square centimeters to square inches

Shop Manual - June 2013

1-29

Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

Volume Cubic inches to cubic centimeters in3

0

1

2

3

4

5

6

7

8

9

in3

cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) -

-

16.387

32.774

49.161

65.548

81.935

98.322

114.709 131.096 147.484

-

10 163.871 180.258 196.645 213.032 229.419 245.806 262.193 278.580 294.967 311.354 10

A

20 327.741 344.128 360.515 376.902 393.289 409.677 426.064 442.451 458.838 475.225 20 30 491.612 507.999 524.386 540.773 557.160 573.547 589.934 606.321 622.708 639.095 30

RI C

40 655.482 671.869 688.257 704.644 721.031 737.418 753.805 770.192 786.579 802.966 40 50 819.353 835.740 852.127 868.514 884.901 901.288 917.675 934.062 950.449 966.837 50 60 983.224 999.611 1015.998 1032.385 1048.772 1065.159 1081.546 1097.933 1114.320 1130.707 60

AM E

70 1147.094 1163.481 1179.868 1196.255 1212.642 1229.030 1245.417 1261.804 1278.191 1294.578 70 80 1310.965 1327.352 1343.739 1360.126 1376.513 1392.900 1409.287 1425.674 1442.061 1458.448 80 90 1474.835 1491.222 1507.610 1523.997 1540.384 1556.771 1573.158 1589.545 1605.932 1622.319 90 100 1638.706 1655.093 1671.480 1687.867 1704.254 1720.641 1737.028 1753.415 1769.802 1786.190 100

cm3 (cc)

0

1 3

3 3

4

3

in

in

-

-

0.0610

0.1220

10

0.6102

0.6713

20

1.2205

30

3

3

6

7 3

8 3

cm3

9 3

(cc) 3

in

in

in

in

in

in

0.1831

0.2441

0.3051

0.3661

0.4272

0.4882

0.5492

-

0.7323

0.7933

0.8543

0.9153

0.9764

1.0374

1.0984

1.1594

10

1.2815

1.3425

1.4035

1.4646

1.5256

1.5866

1.6476

1.7086

1.7697

20

1.8307

1.8917

1.9527

2.0138

2.0748

2.1358

2.1968

2.2579

2.3189

2.3799

30

40

2.4409

2.5019

2.5630

2.6240

2.6850

2.7460

2.8071

2.8681

2.9291

2.9901

40

50

3.0512

3.1122

3.1732

3.2342

3.2952

3.3563

3.4173

3.4783

3.5393

3.6004

50

60

3.6614

3.7224

3.7834

3.8444

3.9055

3.9665

4.0275

4.0885

4.1496

4.2106

60

70

4.2716

4.3326

4.3937

4.4547

4.5157

4.5767

4.6377

4.6988

4.7598

4.8208

70

80

4.8818

4.9429

5.0039

5.0649

5.1259

5.1870

5.2480

5.3090

5.3700

5.4310

80

90

5.4921

5.5531

5.6141

5.6751

5.7362

5.7972

5.8582

5.9192

5.9803

6.0413

90

100

6.1023

6.1633

6.2243

6.2854

6.3464

6.4074

6.4684

6.5295

6.5905

6.6515

100

1-30

LA

in

SA

in

5

NY

3

2

TI N

Cubic centimeters to cubic inches

Shop Manual - June 2013

Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

U.S. Gallons to liters U.S. gal -

0

1

2

3

4

5

6

7

8

9

liters

liters

liters

liters

liters

liters

liters

liters

liters

liters

-

3.7854

7.5709

11.3563 15.1417 18.9271 22.7126 26.4980 30.2834 34.0688

U.S. gal -

37.8543 41.6397 45.4251 49.2106 52.9960 56.7814 60.5668 64.3523 68.1377 71.9231

10

20

75.7085 79.4940 83.2794 87.0648 90.8502 94.6357 98.4211 102.2065 105.9920 109.7774

20

30

113.5628 117.3482 121.1337 124.9191 128.7045 132.4899 136.2754 140.0608 143.8462 147.6317

30

40

151.4171 155.2025 158.9879 162.7734 166.5588 170.3442 174.1296 177.9151 181.7005 185.4859

40

50

189.2714 193.0568 196.8422 200.6276 204.4131 208.1985 211.9839 215.7693 219.5548 223.3402

50

60

227.1256 230.9110 234.6965 238.4819 242.2673 246.0528 249.8382 253.6236 257.4090 261.1945

60

70

264.9799 268.7653 272.5507 276.3362 280.1216 283.9070 287.6925 291.4779 295.2633 299.0487

70

80

302.8342 306.6196 310.4050 314.1904 317.9759 321.7613 325.5467 329.3321 333.1176 336.9030

80

90

340.6884 344.4739 348.2593 352.0447 355.8301 359.6156 363.4010 367.1864 370.9718 374.7573

90

AM E

RI C

A

10

100 378.5427 382.3281 386.1136 389.8990 393.6844 397.4698 401.2553 405.0407 408.8261 412.6115 100

3

4

5

6

7

8

9

gal

gal

gal

gal

gal

gal

gal

0.7925

1.0567

1.3209

1.5850

1.8492

2.1134

2.3775

-

LA

1

2

gal

gal

gal

-

-

0.2642

0.5283

10

2.6417

2.9059

3.1701

3.4342

3.6984

3.9626

4.2268

4.4909

4.7551

5.0193

10

20

5.2834

5.5476

5.8118

6.0760

6.3401

6.6043

6.8685

7.1326

7.3968

7.6610

20

30

7.9252

8.1893

8.4535

8.7177

8.9818

9.2460

9.5102

9.7744 10.0385 10.3027

30

40

10.5669 10.8311 11.0952 11.3594 11.6236 11.8877 12.1519 12.4161 12.6803 12.9444

40

50

13.2086 13.4728 13.7369 14.0011 14.2653 14.5295 14.7936 15.0578 15.3220 15.5861

50

60

15.8503 16.1145 16.3787 16.6428 16.9070 17.1712 17.4354 17.6995 17.9637 18.2279

60

NY

0

SA

liters

TI N

Liters to U.S. Gallons liters

70

18.4920 18.7562 19.0204 19.2846 19.5487 19.8129 20.0771 20.3412 20.6054 20.8696

70

80

21.1338 21.3979 21.6621 21.9263 22.1904 22.4546 22.7188 22.9830 23.2471 23.5113

80

90

23.7755 24.0397 24.3038 24.5680 24.8322 25.0963 25.3605 25.6247 25.8889 26.1530

90

100 26.4172 26.6814 26.9455 27.2097 27.4739 27.7381 28.0022 28.2664 28.5306 28.7947 100

Shop Manual - June 2013

1-31

Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

U.K. Gallons to Liters lmp gal -

0

1

2

3

4

5

6

7

8

9

liters

liters

liters

liters

liters

liters

liters

liters

liters

liters

-

4.5459

9.0918

13.6377 18.1836 22.7295 27.2754 31.8213 36.3672 40.9131

lmp gal -

45.4590 50.0049 54.5508 59.0967 63.6426 68.1885 72.7344 77.2803 81.8262 86.3721

10

20

90.9180 95.4639 100.0098 104.5557 109.1016 113.6475 118.1934 122.7393 127.2852 131.8311

20

30

136.3770 140.9229 145.4688 150.0147 154.5606 159.1065 163.6524 168.1983 172.7442 177.2901

30

40

181.8360 186.3819 190.9278 195.4737 200.0196 204.5655 209.1114 213.6573 218.2032 222.7491

40

50

227.2950 231.8409 236.3868 240.9327 245.4786 250.0245 254.5704 259.1163 263.6622 268.2081

50

60

272.7540 277.2999 281.8458 286.3917 290.9376 295.4835 300.0294 304.5753 309.1212 313.6671

60

70

318.2130 322.7589 327.3048 331.8507 336.3966 340.9425 345.4884 350.0343 354.5802 359.1261

70

80

363.6720 368.2179 372.7638 377.3097 381.8556 386.4015 390.9474 395.4933 400.0392 404.5851

80

90

409.1310 413.6769 418.2228 422.7687 427.3146 431.8605 436.4064 440.9523 445.4982 450.0441

90

AM E

RI C

A

10

100 454.5900 459.1359 463.6818 468.2277 472.7736 477.3195 481.8654 486.4113 490.9572 495.5031 100

1

2

3

4

5

6

7

8

9

gal

gal

gal

gal

gal

gal

gal

gal

gal

gal

-

-

0.2200

0.4400

0.6599

0.8799

1.0999

1.3199

1.5399

1.7598

1.9798

-

10

2.1998

2.4198

2.6398

2.8597

3.0797

3.2997

3.5197

3.7397

3.9596

4.1796

10

20

4.3996

4.6196

4.8396

5.0595

5.2795

5.4995

5.7195

5.9395

6.1594

6.3794

20

30

6.5994

6.8194

7.0394

7.2593

7.4793

7.6993

7.9193

8.1393

8.3592

8.5792

30

40

8.7992

9.0192

9.2392

9.4591

9.6791

9.8991 10.1191 10.3391 10.5590 10.7790

40

50

10.9990 11.2190 11.4390 11.6589 11.8789 12.0989 12.3189 12.5389 12.7588 12.9788

50

60

13.1988 13.4188 13.6388 13.8587 14.0787 14.2987 14.5187 14.7387 14.9586 15.1786

60

70

15.3986 15.6186 15.8386 16.0585 16.2785 16.4985 16.7185 16.9385 17.1584 17.3784

70

80

17.5984 17.8184 18.0384 18.2583 18.4783 18.6983 18.9183 19.1383 19.3582 19.5782

80

90

19.7982 20.0182 20.2382 20.4581 20.6781 20.8981 21.1181 21.3381 21.5580 21.7780

90

NY

LA

0

SA

liters

TI N

Liters to U.K. Gallons liters

100 21.9980 22.2180 22.4380 22.6579 22.8779 23.0979 23.3179 23.5379 23.7578 23.9778 100

1-32

Shop Manual - June 2013

Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

Weight

2

3

4

5

6

7

8

9

kg

kg

kg

kg

kg

kg

kg

kg

kg

kg

-

-

0.454

0.907

1.361

1.814

2.268

2.722

3.175

3.629

4.082

-

10

4.536

4.989

5.443

5.897

6.350

6.804

7.257

7.711

8.165

8.618

10

20

9.072

9.525

9.979

10.433

10.886

11.340

11.793

12.247

12.701

13.154

20

30

13.608

14.061

14.515

14.968

15.422

15.876

16.329

16.783

17.236

17.690

30

40

18.144

18.597

19.051

19.504

19.958

20.412

20.865

21.319

21.772

22.226

40

50

22.680

23.133

23.587

24.040

24.494

24.947

25.401

25.855

26.308

26.762

50

60

27.215

27.669

28.123

28.576

29.030

29.483

29.937

30.391

30.844

31.298

60

70

31.751

32.205

32.658

33.112

33.566

34.019

34.473

34.926

35.380

35.834

70

80

36.287

36.741

37.194

37.648

38.102

38.555

39.009

39.462

39.916

40.370

80

90

40.823

41.277

41.730

42.184

42.637

43.091

43.545

43.998

44.452

44.905

90

100 45.359

45.813

46.266

46.720

47.173

47.627

48.081

48.534

48.988

49.441 100

Kilogram to Pound 1

2

lbs.

lbs.

lbs.

-

-

2.205

10

22.046

20

44.092

30

66.139

68.343

40

88.185

90.389

lbs.

3

4

5

6

7

8

9

lbs.

lbs.

lbs.

lbs.

lbs.

lbs.

lbs.

4.409

6.614

8.818

11.023

13.228

15.432

17.637

19.842

-

24.251

26.455

28.660

30.865

33.069

35.274

37.479

39.683

41.888

10

46.297

48.502

50.706

52.911

55.116

57.320

59.525

61.729

63.934

20

70.548

72.752

74.957

77.162

79.366

81.571

83.776

85.980

30

92.594

94.799

97.003

99.208 101.413 103.617 105.822 108.026

40

50

110.231 112.436 114.640 116.845 119.049 121.254 123.459 125.663 127.868 130.073

50

60

132.277 134.482 136.686 138.891 141.096 143.300 145.505 147.710 149.914 152.119

60

70

154.323 156.528 158.733 160.937 163.142 165.347 167.551 169.756 171.960 174.165

70

80

176.370 178.574 180.779 182.983 185.188 187.393 189.597 191.802 194.007 196.211

80

90

198.416 200.620 202.825 205.030 207.234 209.439 211.644 213.848 216.053 218.257

90

NY

LA

0

SA

kg

A

1

TI N

lbs.

AM E

0

RI C

Pound to Kilogram

kg

100 220.462 222.667 224.871 227.076 229.280 231.485 233.690 235.894 238.099 240.304 100

Shop Manual - June 2013

1-33

Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

Newton to Kilogram 10

20

30

40

50

60

70

80

90

kg

kg

kg

kg

kg

kg

kg

kg

kg

kg

-

-

1.020

2.039

3.059

4.079

5.099

6.118

7.138

8.158

9.177

-

100

10.197

11.217

12.237

13.256

14.276

15.296

16.316

17.335

18.355

19.375

100

200

20.394

21.414

22.434

23.454

24.473

25.493

26.513

27.532

28.552

29.572

200

300

30.592

31.611

32.631

33.651

34.670

35.690

36.710

37.730

38.749

39.769

300

400

40.789

41.809

42.828

43.848

44.868

45.887

46.907

47.927

48.947

500

50.986

52.006

53.025

54.045

55.065

56.085

57.104

58.124

59.144

60.163

500

600

61.183

62.203

63.223

64.242

65.262

66.282

67.302

68.321

69.341

70.361

600

700

71.380

72.400

73.420

74.440

75.459

76.479

77.499

78.518

79.538

80.558

700

800

81.578

82.597

83.617

84.637

85.656

86.676

87.696

88.716

89.735

90.755

800

900

91.775

92.795

93.814

94.834

95.854

96.873

97.893

A

0

49.966

RI C

AM E

N

98.913

N

400

99.933 100.952 900

1000 101.972 102.992 104.011 105.031 106.051 107.071 108.090 109.110 110.130 111.149 1000

1

2

3

5

6

7

8

9

N

N

N

N

N

N

N

N

N

N

-

-

9.81

19.61

29.42

39.23

49.03

58.84

68.65

78.45

88.26

-

10

98.07

107.87

117.68

127.49

137.29

147.10

156.91

166.71

176.52

186.33

10

20

196.13

205.94

215.75

225.55

235.36

245.17

254.97

264.78

274.59

284.39

20

30

294.20

304.01

313.81

323.62

333.43

343.23

353.04

362.85

372.65

382.46

30

40

392.27

402.07

411.88

421.69

431.49

441.30

451.11

460.91

470.72

480.53

40

50

490.34

500.14

509.95

519.76

529.56

539.37

549.18

558.98

568.79

578.60

50

60

588.40

598.21

608.02

617.82

627.63

637.44

647.24

657.05

666.86

676.66

60

70

686.47

696.28

706.08

715.89

725.70

735.50

745.31

755.12

764.92

774.73

70

80

784.54

794.34

804.15

813.96

823.76

833.57

843.38

853.18

862.99

872.80

80

90

882.60

892.41

902.22

912.02

921.83

931.64

941.44

951.25

961.06

970.86

90

100

980.67

990.48 1000.28 1010.09 1019.90 1029.70 1039.51 1049.32 1059.12 1068.93 100

1-34

LA

4

NY

0

SA

kg

TI N

Kilogram to Newton

Shop Manual - June 2013

kg

Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

Pressure Lb/in² to Kg/cm² lb/ 0 1 2 3 4 5 6 7 8 9 lb/in2 in2 (psi) kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 (psi) -

0.0703

0.1406

0.2109

0.2812

0.3515

0.4218

0.4921

0.5625

0.6328

-

10

0.7031

0.7734

0.8437

0.9140

0.9843

1.0546

1.1249

1.1952

1.2655

1.3358

10

20

1.4061

1.4764

1.5468

1.6171

1.6874

1.7577

1.8280

1.8983

1.9686

2.0389

20

30

2.1092

2.1795

2.2498

2.3201

2.3904

2.4607

2.5311

2.6014

2.6717

2.7420

30

40

2.8123

2.8826

2.9529

3.0232

3.0935

3.1638

3.2341

3.3044

3.3747

3.4450

40

50

3.5154

3.5857

3.6560

3.7263

3.7966

3.8669

3.9372

4.0075

4.0778

4.1481

50

60

4.2184

4.2887

4.3590

4.4293

4.4996

4.5700

4.6403

4.7106

4.7809

4.8512

60

70

4.9215

4.9918

5.0621

5.1324

5.2027

5.2730

5.3433

5.4136

5.4839

5.5543

70

80

5.6246

5.6949

5.7652

5.8355

5.9058

5.9761

6.0464

6.1167

6.1870

6.2573

80

90

6.3276

6.3979

6.4682

6.5386

6.6089

6.6792

6.7495

6.8198

6.8901

6.9604

90

100

7.0307

7.1010

7.1713

7.2416

7.3119

7.3822

7.4525

7.5228

7.5932

7.6635

100

-

0

1

2

lb/in2

lb/in2

lb/in2

(psi) -

(psi) 14.22

(psi) 28.45

RI C

AM E

TI N

kg/ cm2

LA

Kg/cm² to Lb/in²

A

-

3

4

5

6

7

8

9

lb/in2

lb/in2

lb/in2

lb/in2

lb/in2

lb/in2

lb/in2

(psi) 56.89

(psi) 71.12

(psi) 85.34

(psi) 99.56

(psi) 42.67

(psi) (psi) 113.78 128.01

kg/cm2

-

142.23 156.45 170.68 184.90 199.12 213.35 227.57 241.79 256.01 270.24

10

20

284.46 298.68 312.91 327.13 341.35 355.58 369.80 384.02 398.24 412.47

20

30

426.69 440.91 455.14 469.36 483.58 497.81 512.03 526.25 540.47 554.70

30

40

568.92 583.14 597.37 611.59 625.81 640.04 654.26 668.48 682.70 696.93

40

50

711.15 725.37 739.60 753.82 768.04 782.27 796.49 810.71 824.93 839.16

50

60

853.38 867.60 881.83 896.05 910.27 924.50 938.72 952.94 967.16 981.39

60

70

995.61 1009.83 1024.06 1038.28 1052.50 1066.73 1080.95 1095.17 1109.39 1123.62

70

80

1137.84 1152.06 1166.29 1180.51 1194.73 1208.96 1223.18 1237.40 1251.62 1265.85

80

90

1280.07 1294.29 1308.52 1322.74 1336.96 1351.19 1365.41 1379.63 1393.85 1408.08

90

100

1422.30 1436.52 1450.75 1464.97 1479.19 1493.42 1507.64 1521.86 1536.08 1550.31

100

SA

NY

10

Shop Manual - June 2013

1-35

Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

Kg/cm² to Kpa kg/ cm2

kg/ cm2

1

2

3

4

5

6

7

8

9

Kpa

Kpa

Kpa

Kpa

Kpa

Kpa

Kpa

Kpa

Kpa

Kpa

-

-

98.1

196.1

294.2

392.3

490.3

588.4

686.5

784.5

882.6

10

980.7

1078.7

1176.8

1274.9 1372.9 1471.0 1569.1 1667.1 1765.2 1863.3

10

20

1961.3 2059.4 2157.5 2255.5 2353.6 2451.7 2549.7 2647.8 2745.9 2843.9

20

30

2942.0 3040.1 3138.1 3236.2 3334.3 3432.3 3530.4 3628.5 3726.5 3824.6

30

40

3922.7 4020.7

4609.1 4707.2 4805.3

40

50

4903.4 5001.4 5099.5 5197.6 5295.6 5393.7 5491.8 5589.8 5687.9 5786.0

50

60

5884.0 5982.1 6080.2 6178.2 6276.3 6374.4 6472.4 6570.5 6668.6 6766.6

60

70

6864.7 6962.8 7060.8 7158.9 7257.0 7355.0 7453.1 7551.2 7649.2 7747.3

70

80

7845.4 7943.4 8041.5 8139.6 8237.6 8335.7 8433.8 8531.8 8629.9 8728.0

80

90

8826.0 8924.1 9022.2 9120.2 9218.3 9316.4 9414.4 9512.5 9610.6 9708.6

90

100

9806.7 9904.8 10002.8 10100.9 10199.0 10297.0 10395.1 10493.2 10591.2 10689.3

100

4511.1

RI C

4216.9 4314.9 4413.0

AM E

4118.8

A

0

-

Kpa

0

100

200

300

TI N

Kpa to Kg/cm² 400

500

600

700

800

900

Kpa

kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 -

1.020

2.039

1000

10.197

11.217

12.237

13.256

2000

20.394

21.414

22.434

3000

30.592

31.611

4000

40.789

5000

50.986

6000

61.183

7000

71.380

9000

5.099

6.118

7.138

8.158

9.177

-

14.276

15.296

16.316

17.335

18.355

19.375

1000

23.454

24.473

25.493

26.513

27.532

28.552

29.572

2000

32.631

33.651

34.670

35.690

36.710

37.730

38.749

39.769

3000

41.809

42.828

43.848

44.868

45.887

46.907

47.927

48.947

49.966

4000

52.006

53.025

54.045

55.065

56.085

57.104

58.124

59.144

60.163

5000

62.203

63.223

64.242

65.262

66.282

67.302

68.321

69.341

70.361

6000

72.400

73.420

74.440

75.459

76.479

77.499

78.518

79.538

80.558

7000

81.578

82.597

83.617

84.637

85.656

86.676

87.696

88.716

89.735

90.755

8000

91.775

92.795

93.814

94.834

95.854

96.873

97.893

98.913

99.933 100.952 9000

NY

SA

8000

3.059

4.079

LA

-

10000 101.972 102.992 104.011 105.031 106.051 107.071 108.090 109.110 110.130 111.149 10000

1-36

Shop Manual - June 2013

Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

Torque Ft·lbs to Kg·m 1

2

3

4

5

6

7

8

9

kg·m

kg·m

kg·m

kg·m

kg·m

kg·m

kg·m

kg·m

kg·m

kg·m

-

-

0.138

0.277

0.415

0.553

0.691

0.830

0.968

1.106

1.244

-

10

1.383

1.521

1.659

1.797

1.936

2.074

2.212

2.350

2.489

2.627

10

20

2.765

2.903

3.042

3.180

3.318

3.457

3.595

3.733

3.871

4.010

20

30

4.148

4.286

4.424

4.563

4.701

4.839

4.977

5.116

5.254

5.392

30

40

5.530

5.669

5.807

5.945

6.083

6.222

6.360

50

6.913

7.051

7.190

7.328

7.466

7.604

7.743

60

8.296

8.434

8.572

8.710

8.849

8.987

9.125

70

9.678

9.816

9.955

10.093

10.231

10.370

80

11.061

11.199

11.337

11.476

11.614

90

12.443

12.582

12.720

12.858

100

13.826

13.964

14.103

14.241

0

1

2

ft·lbs

ft·lbs

-

-

10

Kg·m to Ft·lbs

RI C

ft·lbs

6.636

6.775

40

7.881

8.019

8.157

50

9.263

9.402

9.540

60

10.508

10.646

10.784

10.923

70

11.752

11.890

12.029

12.167

12.305

80

12.996

13.135

13.273

13.411

13.549

13.688

90

14.379

14.517

14.656

14.794

14.932

15.070

100

kg·m

AM E

6.498

4

5

6

7

8

9

ft·lbs

ft·lbs

ft·lbs

ft·lbs

ft·lbs

ft·lbs

ft·lbs

ft·lbs

7.23

14.47

21.70

28.93

36.17

43.40

50.63

57.86

65.10

-

72.33

79.56

86.80

94.03

101.26

108.50

115.73

122.96

130.19

137.43

10

20

144.66

151.89

159.13

166.36

173.59

180.83

188.06

195.29

202.52

209.76

20

30

216.99

224.22

231.46

238.69

245.92

253.16

260.39

267.62

274.85

282.09

30

40

289.32

296.55

303.79

311.02

318.25

325.49

332.72

339.95

347.18

354.42

40

50

361.65

368.88

376.12

383.35

390.58

397.82

405.05

412.28

419.51

426.75

50

60

433.98

441.21

448.45

455.68

462.91

470.15

477.38

484.61

491.84

499.08

60

70

506.31

513.54

520.78

528.01

535.24

542.48

549.71

556.94

564.17

571.41

70

80

578.64

585.87

593.11

600.34

607.57

614.81

622.04

629.27

636.50

643.74

80

90

650.97

658.20

665.44

672.67

679.90

687.14

694.37

701.60

708.83

716.07

90

100

723.30

730.53

737.77

745.00

752.23

759.47

766.70

773.93

781.16

788.40

100

NY

LA

3

SA

kg·m

A

0

TI N

ft·lbs

Shop Manual - June 2013

1-37

Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

Kg·m to N·m 1

2

3

4

5

6

7

8

9

N·m

N·m

N·m

N·m

N·m

N·m

N·m

N·m

N·m

N·m

-

-

9.81

19.61

29.42

39.23

49.03

58.84

68.65

78.45

88.26

-

10

98.07

107.87

117.68

127.49

137.29

147.10

156.91

166.71

176.52

186.33

10

20

196.13

205.94

215.75

225.55

235.36

245.17

254.97

264.78

274.59

284.39

20

30

294.20

304.01

313.81

323.62

333.43

343.23

353.04

362.85

372.65

382.46

30

40

392.27

402.07

411.88

421.69

431.49

441.30

451.11

460.91

470.72

50

490.34

500.14

509.95

519.76

529.56

539.37

549.18

558.98

568.79

578.60

50

60

588.40

598.21

608.02

617.82

627.63

637.44

647.24

657.05

666.86

676.66

60

70

686.47

696.28

706.08

715.89

725.70

735.50

745.31

755.12

764.92

774.73

70

80

784.54

794.34

804.15

813.96

823.76

833.57

843.38

853.18

862.99

872.80

80

90

882.60

892.41

902.22

912.02

921.83

931.64

961.06

970.86

90

100

980.67

990.48 1000.28 1010.09 1019.90 1029.70 1039.51 1049.32 1059.12 1068.93 100

941.44

A

0

480.53

RI C

AM E

kg·m

951.25

kg·m

40

10

20

30

50

60

70

80

90

kg·m

kg·m

kg·m

kg·m

kg·m

kg·m

kg·m

kg·m

kg·m

kg·m

-

-

1.020

2.039

3.059

4.079

5.099

6.118

7.138

8.158

9.177

-

100

10.197

11.217

12.237

13.256

14.276

15.296

16.316

17.335

18.355

19.375

10

200

20.394

21.414

22.434

23.454

24.473

25.493

26.513

27.532

28.552

29.572

20

300

30.592

31.611

32.631

33.651

34.670

35.690

36.710

37.730

38.749

39.769

30

400

40.789

41.809

42.828

43.848

44.868

45.887

46.907

47.927

48.947

49.966

40

500

50.986

52.006

53.025

54.045

55.065

56.085

57.104

58.124

59.144

60.163

50

600

61.183

62.203

63.223

64.242

65.262

66.282

67.302

68.321

69.341

70.361

60

700

71.380

72.400

73.420

74.440

75.459

76.479

77.499

78.518

79.538

80.558

70

800

81.578

82.597

83.617

84.637

85.656

86.676

87.696

88.716

89.735

90.755

80

900

91.775

92.795

93.814

94.834

95.854

96.873

97.893

98.913

99.933 100.952

90

LA

40

NY

0

SA

N·m

TI N

N·m to Kg·m N·m

1000 101.972 102.992 104.011 105.031 106.051 107.071 108.090 109.110 110.130 111.149 100

1-38

Shop Manual - June 2013

Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

Temperature A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading (or vice versa) is to enter the following table in the center (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. To convert from Fahrenheit to Centigrade degrees, consider the center column as Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.

SA

NY

LA

TI N

AM E

RI C

A

To convert from Centigrade to Fahrenheit degrees, consider the center column as Centigrade values, and read the corresponding Fahrenheit temperature on the right.

Shop Manual - June 2013

1-39

Introduction

SY195/205/215/225C9 Crawler Hydraulic Excavator

1°C = 33.8°F °F

°C

°F

°C

°F

°C

°F

-40

-40.0

-11.7

11

51.8

7.8

46

114.8

27.2

81

177.8

-37.2

-35

-31.0

-11.1

12

53.6

8.3

47

116.6

27.8

82

179.6

-34.4

-30

-22.0

-10.6

13

55.4

8.9

48

118.4

28.3

83

181.4

-31.7

-25

-13.0

-10.0

14

57.2

9.4

49

120.2

28.9

84

183.2

-28.9 -28.3

-2 -20 -19

-4.0 -2.2

-9.4 -8.9

15 16

59.0 60.8

10.0 10.6

50 51

122.0 123.8

29.4 30.0

85 86

185.0 186.8

-27.8

-18

-0.4

-8.3

17

62.6

11.1

52

125.6

30.6

87

188.6

-27.2

-17

1.4

-7.8

18

64.4

11.7

53

127.4

31.1

88

190.4

-26.7

-16

3.2

-7.2

19

66.2

12.2

54

129.2

31.7

89

192.2

-26.1 -25.6

-15 -14

5.0 6.8

-6.7 -6.1

20 21

68.0 69.8

12.8 13.3

55 56

131.0 132.8

32.2 32.8

90 91

194.0 195.8

-25.0

-13

8.6

-5.6

22

71.6

13.9

57

134.6

33.3

92

197.6

-24.4

-12

10.4

-5.0

23

73.4

14.4

58

136.4

33.9

93

199.4

-23.9

-11

12.2

-4.4

24

75.2

15.0

59

138.2

34.4

94

201.2

-23.3 -22.8

-10 -9

14.0 15.8

-3.9 -3.3

25 26

77.0 78.8

15.6 16.1

60 61

140.0 141.8

35.0 35.6

95 96

203.0 204.8

-22.2

-8

17.6

-2.8

27

-21.7

-7

19.4

-2.2

28

-21.1

-6

21.2

-1.7

29

-20.6 -20.0

-5 -4

23.0 24.8

-1.1 -0.6

30 31

-19.4

-3

26.6

0.0

-18.9

-2

28.4

-18.3

-1

-17.8 -17.2

0 1

-16.7

2

TI N

AM E

RI C

-40.0

A

°C

16.7

62

143.6

36.1

97

206.6

82.4

17.2

63

145.4

36.7

98

208.4

84.2

17.8

64

147.2

37.2

99

210.2

86.0 87.8

18.3 18.9

65 66

149.0 150.8

37.8 40.6

100 105

212.0 221.0

32

89.6

19.4

67

152.6

43.3

110

230.0

0.6

33

91.4

20.0

68

154.4

46.1

115

239.0

30.2

1.1

34

93.2

20.6

69

156.2

48.9

120

248.0

32.0 33.8

1.7 2.2

35 36

95.0 96.8

21.1 21.7

70 71

158.0 159.8

51.7 54.4

125 130

257.0 266.0

35.6

2.8

37

98.6

22.2

72

161.6

57.2

135

275.0

3

37.4

3.3

38

100.4

22.8

73

163.4

60.0

140

284.0

4

39.2

3.9

39

102.2

23.3

74

165.2

62.8

145

293.0

-15.0 -14.4

5 6

41.0 42.8

4.4 5.0

40 41

104.0 105.8

23.9 24.4

75 76

167.0 168.8

65.6 68.3

150 155

302.0 311.0

-13.9

7

44.6

5.6

42

107.6

25.0

77

170.6

71.1

160

320.0

-13.3

8

46.4

6.1

43

109.4

25.6

78

172.4

73.9

165

329.0

-12.8

9

48.2

6.7

44

111.2

26.1

79

174.2

76.7

170

338.0

-12.2

10

50.0

7.2

45

113.0

26.7

80

176.0

79.4

175

347.0

-15.6

1-40

NY

SA

-16.1

LA

80.6

Shop Manual - June 2013

Introduction

SA

BLNY ANLA TI KN PAAM E G RI E CA

SY195/205/215/225C9 Crawler Hydraulic Excavator

Shop Manual - June 2013

1-41

SY195/205/215/225C9 Crawler Hydraulic Excavator

BSLAN AYNL AT K IN PAA M GERI E CA

Introduction

1-42

Shop Manual - June 2013

Shop Safety

RI C

Shop Safety

A

SY195/205/215/225C9 Crawler Hydraulic Excavator

2 Shop Safety

SA

NY

LA

TI N

AM E

2.1 Hazard Alert Information .......................................................................................... 2-3 2.2 General Shop Safety ............................................................................................... 2-6 2.2.1 Rules and shop behavior ............................................................................... 2-7 2.2.2 Housekeeping ................................................................................................ 2-7 2.2.3 Shop Liquids Storage..................................................................................... 2-8 2.2.4 Cleaning Parts ............................................................................................... 2-8 2.2.5 Jacking Up the Machine................................................................................. 2-9 2.2.6 Electrical Dangers .......................................................................................... 2-9 2.2.7 Removing Attachments ................................................................................ 2-10 2.2.8 Cleaning the Machine .................................................................................. 2-10 2.2.9 Using the Correct Tools................................................................................ 2-10 2.2.10 Hoisting a Load ...........................................................................................2-11 2.2.11 Appropriate Working Apparel ..................................................................... 2-12 2.2.12 Safety Partners .......................................................................................... 2-12 2.2.13 Two people when engine running .............................................................. 2-13 2.2.14 Driving Pins ................................................................................................ 2-13 2.2.15 Aligning Parts or Components ................................................................... 2-14 2.2.16 Fire Extinguisher and Emergency Exits ..................................................... 2-14 2.2.17 Personal Protective Equipment.................................................................. 2-14 2.2.18 Running the Machine ................................................................................. 2-15 2.2.19 Accumulator ............................................................................................... 2-16 2.2.20 Adding Fluids to a System ......................................................................... 2-16 2.2.21 Track Recoil Springs .................................................................................. 2-17 2.2.22 High-Pressure Fluid Lines.......................................................................... 2-17 2.2.23 Safe Work Preparations ............................................................................. 2-18 2.2.24 Mounting and Dismounting ........................................................................ 2-19 Shop Manual - June 2013

2-1

Shop Safety

SY195/205/215/225C9 Crawler Hydraulic Excavator

SA

NY

LA

TI N

AM E

RI C

A

2.2.25 Battery Hazards ......................................................................................... 2-20 2.2.26 Jump-Start Safety ...................................................................................... 2-21 2.2.27 Disconnecting the System Power .............................................................. 2-21 2.2.28 Lockout/tagout ........................................................................................... 2-22 2.2.29 Sequence of Procedures ........................................................................... 2-22 2.2.30 Chemical hazard ........................................................................................ 2-24 2.2.31 Material Safety Data Sheets (MSDS) ........................................................ 2-24 2.3 Precautions for sling work and giving signals ........................................................ 2-25

2-2

WARNING

Read and understand all safety precautions and instructions in this manual before reading any other manuals provided with this machine and before operating or servicing the machine. Also read the safety information on machine decals before performing any operations. Failure to do so can cause machine damage, personal injury or death.

Shop Manual - June 2013

Shop Safety

SY195/205/215/225C9 Crawler Hydraulic Excavator

2 SHOP SAFETY 2.1 Hazard Alert Information

DANGER

RI C AM E

TI N

The following (ANSI/ISO) signal words are used to inform you that there is a potentially hazardous situation that may lead to damage, personal injury or even death. In this manual, on the machine, part or component decals and different signal words are used to express the potential level of a hazard.

A

Most accidents are usually caused by the failure to follow fundamental repair procedures and safety rules for the system under repair. To avoid accidents it is important to read and understand all information outlined in this manual before performing repairs on the machine system.

LA

Indicates an imminent hazard which WILL result in serious injury or death if message is ignored.

WARNING

SA

NY

Indicates a potentially hazardous situation which COULD result in serious injury or death if message is ignored.

CAUTION

Indicates a potentially hazardous situation which COULD RESULT IN MINOR OR MAJOR INJURY if message is ignored.

NOTICE Indicates THE MACHINE MAY BE DAMAGED if improperly operated or maintained.

Shop Manual - June 2013

2-3

Shop Safety

SY195/205/215/225C9 Crawler Hydraulic Excavator

This is to alert the user of a hazard. It is usually used in a graphic. This symbol is used in a graphic to alert the user to not do something.

RI C AM E

SA

NY

LA

TI N

If any procedures or actions not specified, recommended or allowed in this manual are used, you must be sure that you and others can perform such procedures and actions safely and without damaging the machine. If you are unsure about the safety of some procedures, contact your SANY representative.

A

SANY cannot predict every circumstance that might involve a potential hazard in a repair of the machine. Therefore the safety message in this manual and on the machine may not include all possible safety precautions.

2-4

Shop Manual - June 2013

Shop Safety

SY195/205/215/225C9 Crawler Hydraulic Excavator

WARNING ● Improper repair procedures on this machine can be hazardous and could result in serious injury or even death.

A

● All personnel involved with the repair of this machine must read this manual thoroughly before performing any procedures on this equipment.

AM E

TI N

● All precautions outlined in this manual apply only to intended repair procedures of the machine or system. If you perform any repairs not specifically prohibited, you must be sure that it is safe for you and others. In no event should you or others engage in prohibited uses or actions as described in this manual.

RI C

● Some actions involved in the operation or repair of this machine could cause a serious accident if they are not performed in the manner described in this manual.

SA

NY

LA

● SANY delivers machines that comply with all applicable regulations and standards of the country to which the machines have been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety features and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, contact your SANY representative before performing repairs on this machine.

Shop Manual - June 2013

2-5

Shop Safety

SY195/205/215/225C9 Crawler Hydraulic Excavator

2.2 General Shop Safety

WARNING

RI C AM E

TI N

Always keep in mind, shop safety is NOT something to be studied at the start of a project and then forgotten; most accidents are caused by carelessness, being in a hurry or by simply disreguarding safety rules. Remember this, if you are DILIGENT and follow instructions outlined in this shop manual with care, repair operations can be safe and enjoyable. Safe work practices, should become a force of habit.

A

It's important to establish good shop safety rules for everyone who enters or uses the shop area. Implementing shop safety rules will keep employees safe and provide the most productive environment for working or learning. Post rules where they can clearly be viewed at all times. If necessary, provide shop personnel with a written copy of the rules and discuss any questions or confusion with them.

SA

NY

LA

● Mistakes in operation are extremely hazardous. Read the Safety, Operation & Maintenance Manual that came with the machine carefully before operating the machine. Failure to follow this alert could result in serious injury or death.

2-6

Shop Manual - June 2013

Shop Safety

SY195/205/215/225C9 Crawler Hydraulic Excavator

2.2.1 Rules and shop behavior ● Study all shop rules relating to the procedure carefully and constantly apply them. When in doubt about any task, get help! DO NOT take chances.

RI C AM E

● The shop is a place to work, not play. It is NOT a place for “horseplay”. A “joker” in a repair shop is a “walking hazard” to everyone. Daydreaming or socializing on the job also increases your chances of injury.

A

● Know your job. It is foolish, and often disastrous, to make repairs to a machine without first receiving proper instructions. Always use the shop manual when performing any repair tasks. Get additional help if you are NOT sure what must be done or how a task should be performed.

CA13082101

TI N

● If you must smoke, smoke only in the area provided for smoking. Never smoke while on the shop floor or work area.

2.2.2 Housekeeping

NY

LA

● Oils, grease, fuel, antifreeze or any fluid spills should be mopped up immediately. These items pose a serious slip hazard. Regardless of who was responsible for the spill, it is your job as a shop employee to secure and clean up the spill area.

SA

● Keep the shop clean. Scrap or old parts should be disposed of properly. Never allow them to remain on the bench or shop floor. ● All equipment and tools must be put back in their proper storage areas after each use. It's imperative that you do not let a shop become cluttered and disorganized in order to prevent accidents.

CA13082102

● Always keep in mind, proper house cleaning is vital for a safe and pleasant work environment. Shop Manual - June 2013

2-7

Shop Safety

SY195/205/215/225C9 Crawler Hydraulic Excavator

2.2.3 Shop Liquids Storage

A

● Liquids, cleaning solvents or machine fluids should be properly stored in an area away from work locations. These storage areas should be ventilated to an outdoor location to avoid any vapor accumulation in a confined shop area. Follow all OSHA regulations regarding fluid storage.

CA13082103

TI N

● Never smoke or bring open flames around liquids, doing so could result in an unexpected fire or explosion.

AM E

● Never store liquids in containers that are not properly labeled for that liquid. Confusion could result in equipment damage, fire or an unexpected explosion.

RI C

● Never leave open containers of liquids sitting around. These could spill or catch fire. Always read the container label for information on storage and handling of the liquids.

LA

● Never handle liquids without using personal protective equipment. Treat all liquids with caution.

NY

2.2.4 Cleaning Parts

SA

Never use gasoline, diesel fuel or similar flammable liquids to clean parts. Always use approved non-flammable solvents to clean parts. Failure to do so could result in explosion or fire.

CA13082104

2-8

Shop Manual - June 2013

Shop Safety

SY195/205/215/225C9 Crawler Hydraulic Excavator

2.2.5 Jacking Up the Machine ● If you will be working under the machine always use approved jack stands that will support the weight of the machine you are working on.

A

● Never rely on the hydraulics of the machine or a hydraulic jack to support the machine during repairs.

TI N

● When testing electrical circuits, always be aware of what you will be checking in these systems. High voltage or high amp circuits could damage your equipment or cause a spark, explosion or possible fire.

CZ335-1102078

AM E

2.2.6 Electrical Dangers

RI C

● Always lower the work equipment to the ground and check the stability of the machine before going under the machine.

NY

LA

● Before performing any repairs or testing on an electrical system be sure of the system voltage dangers. Always check the circuit to be sure it is off before performing any repairs.

SA

● When working around flammable liquids or explosive systems, use only approved antiexplosion proof work lamps. Non-approved work lamps can cause an explosion or fire. CA13082105

Shop Manual - June 2013

2-9

Shop Safety

SY195/205/215/225C9 Crawler Hydraulic Excavator

2.2.7 Removing Attachments ● If you will be removing large heavy attachments from the machine, always be sure to use the correct lifting equipment rated for the capacity of the load you will be lifting.

RI C

A

● After the attachment or part has been removed, store it where it cannot fall or move. Always be sure what you are storing is sitting stable on a stable surface and clear of all walkways or fire exits.

TI N

● Always use high-pressure hot water and mild, nonflammable grease-cutting soaps or cleaning agents to clean the machine parts. Never use flammable or caustic cleaning agents.

AM E

2.2.8 Cleaning the Machine

CA13082106

LA

● Never use high-pressure steam cleaners to clean the machine. Steam cleaners will damage the paint, hoses or electrical system.

NY

● Never pressure-wash or flood the inside of an operator cab. This will damage sensitive electrical components.

SA

2.2.9 Using the Correct Tools ● Always use the proper authorized tools for the job. Using tools that are not authorized, incorrect for the job, defective or damaged could cause serious injury. ● Keep all tools in good condition, learn the correct way to use them.

2-10

Shop Manual - June 2013

CA13082107

Shop Safety

SY195/205/215/225C9 Crawler Hydraulic Excavator

● Before starting the work, thoroughly check the tools, machine, forklift, crane, service car, etc. ● Keep your tools clean, and when the job is complete, take inventory of the tools you were using to be sure no tools were left in the machine.

A

● Always put shop tools back in there proper storage location when finished.

ZX215-1000033

AM E

RI C

● If welding repairs are needed, always have a trained, experienced or certified welder carry out the work.

2.2.10 Hoisting a Load

TI N

If you will be lifting parts or components that weigh more than 35 lbs (16 kg), it is important to follow some basic rules.

LA

● Always use the appropriate lifting equipment such as hoist, crane, forklift etc. to handle a loads if possible.

NY

● Be sure the lifting equipment is in good condition and rated for the load you are about to lift.

SA

● If straps are to be used, ensure they are in good condition and rated for the load to be lifted with them.

CA13082108

● If you must lift the load by hand, keep your back straight and parallel with the load, and lift the load using your leg muscles to avoid back injuries. Always ask for a lifting assistant.

Shop Manual - June 2013

2-11

Shop Safety

SY195/205/215/225C9 Crawler Hydraulic Excavator

2.2.11 Appropriate Working Apparel Improper or loose clothing, casual dress clothing, jewelry, incorrect shoes or long hair can result in possible injury.

CA13082109

AM E

RI C

A

Make a list of the types of clothing that are not allowed in the shop area. Go over the list with personnel before they start a job.

2.2.12 Safety Partners

LA

TI N

No one should be allowed to perform work operations in any shop alone. It should be a general shop safety rule for a minimum of two people in the shop area at all times when work procedures are performed. A person alone in the shop might not be able to get emergency help in the event of a shop accident.

NY

When working together always maintain clear contact with each other at all times to avoid the occurrence of unexpected incidents. CA13082110

SA

When carrying out any operation with two or more workers, always agree on the operating procedures and signals before starting.

2-12

Shop Manual - June 2013

Shop Safety

SY195/205/215/225C9 Crawler Hydraulic Excavator

2.2.13 Two people when engine running In order to prevent injury, do not perform the service while the engine is running. If the service must be performed while the engine is running, operate only when two people are on the spot and follow the regulations below:

RI C

A

● Always have one operator sit on the operation seat and be ready to turn off the engine at any time. All the operators must keep in touch with each other.

● Do not touch any control lever. If some control lever must be operated, send signal to other people and warn them to transfer to safe place quickly.

AM E

● Set the safety lock control lever to the lock position.

2.2.14 Driving Pins

LA

TI N

● Do not drop or insert the tools and other objects into the fan or fan belt, or the parts will be broken or thrown out.

NY

When using a hammer to drive pins, metal particles may fly off. This may lead to serious eye injuries. Always do the following:

SA

● Always wear a face shield or goggles when striking a metal object with a metal hammer. ● Before performing any of these procedures, be sure all personnel are clear of your work area. ● If possible, avoid using a steel hammer to drive a component or pins in place. Damage to the component may result. Always use a soft or non-ferrous hammer to drive a component or a pin.

Shop Manual - June 2013

CZ335-1102069

2-13

Shop Safety

SY195/205/215/225C9 Crawler Hydraulic Excavator

2.2.15 Aligning Parts or Components ● Be careful when installing or aligning parts or components. ● Avoid using your fingers or hands to position holes or part mating surfaces, serious injury could result if your hand or fingers should get ought between the surfaces.

RI C

A

● Always use tools to align a part or component to avoid any finger or hand injuries.

● It is important to know where all emergency exits and fire extinguishing equipment are located if a fire should occur in the shop.

CA13082111

AM E

2.2.16 Fire Extinguisher and Emergency Exits

LA

TI N

● Before preparing for work, take time and walk around the shop to make a mental note of where all exits and fire equipment are located. If you are performing repairs in the field, always have a fire extinguisher handy and within reach.

CA13082112

NY

● If you do not know how to use a fire extinguisher contact someone who can instruct you in the proper use of this equipment.

SA

2.2.17 Personal Protective Equipment If your shop specifies the use of safety equipment, OSHA requires this equipment to be used when on the shop floor or in the area where this equipment is required. Never allow personnel in the shop area without the proper personnel protective equipment even for a moment. Always keep personnel protective equipment in good condition and replace them as required.

2-14

Shop Manual - June 2013

CZ335-1102002

Shop Safety

SY195/205/215/225C9 Crawler Hydraulic Excavator

2.2.18 Running the Machine Run the machine during repair procedures ONLY if directed to do so in this shop manual. If the machine must be run when making repairs, it is important to follow some basic safety rules. ● Always be aware of rotating components.

RI C

TI N

● The person in the cab must never touch any controls. If a control lever must be operated, always maintain a clear view to the person doing the repair and signal them when you are about to move the control lever.

CZ335-1102077

AM E

● If equipped, all lock levers must be in the LOCK position or the parking brake must be in the PARK position.

A

● During repair operations while the engine is running, one worker must remain in the operator seat of the machine with clear contact between the person performing the repairs on the machine at all times.

CZ335-1102012

SA

NY

LA

● Be aware of hot surfaces. During running operations, most surfaces will be hot, and some surfaces will be extremely hot. If necessary, use personnel protective equipment when working around high temperature surfaces.

● Keep in mind that during running operations, hydraulic systems, cooling systems and fuel systems will be under extremely high pressure and at high temperatures. ● Always use caution when working on or near these systems.

CA13082113

Shop Manual - June 2013

2-15

Shop Safety

SY195/205/215/225C9 Crawler Hydraulic Excavator

2.2.19 Accumulator If the machine is equipped with an accumulator charged with high-pressure nitrogen gas, it is important to follow these basic precautions. ● Do not disassemble the accumulator.

A

● Never expose the accumulator to high heat or open flames.

RI C

● Never weld on the accumulator. ● Never drill or cut on the accumulator.

CZ335-1102085

TI N

● Use only nitrogen gas to charge the accumulator. Unapproved gases could be explosive.

AM E

● Never strike the accumulator.

2.2.20 Adding Fluids to a System

LA

If it should be necessary to add fluids to a system during running operations, always be aware that these systems may be hot and under high pressure.

SA

NY

Before adding fluids, shut the machine down and allow the systems to cool down to outdoor ambient temperatures before removing any caps. Failure to do so may result in serious burns or a sudden loss of fluid.

2-16

CA13082114

Shop Manual - June 2013

Shop Safety

SY195/205/215/225C9 Crawler Hydraulic Excavator

2.2.21 Track Recoil Springs If you are making repairs to a machine equipped with tracks, always be aware of the dangers involved with track recoil springs. This spring is under extreme pressure at all times. If it is disassembled by mistake, the spring may fly out and cause serious injury or death.

2.2.22 High-Pressure Fluid Lines

RI C

CZ335-1102081

AM E

Always stand clear of the track travel path when separating the master link section of the track.

A

Be careful when removing or installing tracks on track-type machines. When removing the master track link the track system may separate suddenly and cause possible injury.

LA

TI N

Always keep in mind that these systems are under high pressure. When inspecting or replacing piping or hoses, always check to be sure the pressure in the system has been relieved before proceeding. Working on a system still under pressure could lead to serious injury, always do as follows:

NY

● If you will be removing a line or component with fluid in the system, always cap and seal the opening to avoid leakage or system contamination.

SA

● Never carry out inspections or replace items while the system is under pressure. ● Never use any part of your body to check or feel for leaks. Always wear safety glasses and leather gloves when checking for leaks and use a piece of wood or cardboard when checking for leaks from small holes. ● If high pressure fluids should penetrate your skin or get into your eyes, seek medical attention immediately.

Shop Manual - June 2013

CZ335-1102082

2-17

Shop Safety

SY195/205/215/225C9 Crawler Hydraulic Excavator

2.2.23 Safe Work Preparations Before starting any repairs, be sure the machine is sitting on a level stable surface.

RI C

A

Lower all the work equipment to a safe and stable position on the ground. Turn the engine OFF and neutralize the work equipment controls by rotating them to the left and right (joystick control) or moving them back and forth (lever control). This function will relieve system pressure.

If equipped, set the hydraulic lock lever in the LOCKED position. If equipped, set the parking brake in the PARK position.

SA

NY

LA

TI N

Be sure all personnel and equipment is clear of your work area and you can be seen by all working personnel especially if performing repairs in the field.

AM E

Block the tracks (if equipped) or wheels (if equipped) with chocks to prevent the machine from moving.

2-18

Shop Manual - June 2013

CA13082115

Shop Safety

SY195/205/215/225C9 Crawler Hydraulic Excavator

2.2.24 Mounting and Dismounting It is important to follow these procedures when mounting or dismounting the equipment: ● Use all hand-holds and step plates on your equipment. ● Never jump off or onto the equipment.

RI C

TI N

● When getting on or off the equipment, always face the equipment and maintain a three-point contact (both feet and one hand or one foot and both hands) with the handrails, steps and platforms to ensure that you support yourself correctly.

CA13031506

AM E

● Never get on or off moving equipment. These actions may lead to serious injury. Always bring the equipment to a full stop and turn the engine OFF.

A

● Wipe off any oil, grease, or mud from your shoes, rails, steps or platforms before getting on the equipment; always keep these areas clean and in good condition.

LA

● Never climb on areas of the machine that are not designated walk areas.

NY

● Never climb on or off the machine with tools, parts or similar objects in your hands.

SA

● Never use machine controls or non-specified points on the equipment to get on or off the machine. ● Use all hand-holds when on the machine.

Shop Manual - June 2013

CA13082116

2-19

Shop Safety

SY195/205/215/225C9 Crawler Hydraulic Excavator

2.2.25 Battery Hazards Working around batteries always poses a hazard, especially if the battery has been in service for a long period of time. Listed below are some basic precautions to be aware of when servicing or working around batteries.

● When working with batteries, always work in a wellventilated area.

RI C

CZ335-1102061

AM E

● Battery gasses are extremely explosive. When opening a battery compartment, always allow ample time for the gasses to escape before servicing the battery.

A

● Always wear personal protective equipment when working around batteries.

CZ335-1102062

NY

LA

TI N

● If the battery is corroded, flush the area with a baking soda and warm water mix.

SA

● If battery acid should get on your skin or in your eyes, flush the area immediately with fresh water and seek medical attention.

CZ335-1102083

2-20

Shop Manual - June 2013

Shop Safety

SY195/205/215/225C9 Crawler Hydraulic Excavator

2.2.26 Jump-Start Safety When using jumper cables to start the machine, connect the positive (+) jumper first, then the negative (-) jumper to a remote location on the chassis away from the battery.

A

CAUTION

TI N

Before starting any repair operations, remove the battery leads from the battery or set the main disconnect on the machine in the OFF position.

CA13082117

AM E

2.2.27 Disconnecting the System Power

RI C

Never use a welder or a machine with a higher voltage system to jump-start the machine. Doing so may damage the machine’s electrical system or cause an unexpected explosion or fire resulting in minor or major injury.

LA

For the location of the machine main electrical disconnect switch, refer to the machines Safety, Operation & Maintenance Manual for location and procedures.

NY

If the battery must be disconnected, remove the negative (-) terminal clamp first then remove the positive (+) clamp last.

SA

When reconnecting the battery, be sure every electrical system switch is in the OFF position, connect the positive clamp (+) first, then the negative clamp(-) last.

CA13082118

Shop Manual - June 2013

2-21

Shop Safety

SY195/205/215/225C9 Crawler Hydraulic Excavator

2.2.28 Lockout/tagout

RI C

TI N

Only authorized employees performing repairs on the machine shall perform Lockout/Tagout in accordance with this procedure listed below.

AM E

2.2.29 Sequence of Procedures

A

Due to the size and complexity of this machine, Lockout and Tagout procedures may be required by your company to ensure the safety of yourself and others involved in the repair process of the machine. While work is in progress, all power sources must be disabled, locked and tagged with a warning label. Lockout/Tagout procedure establishes the minimum requirements used to isolate all power sources from potentially hazardous energy, and to ensure that the machine is “locked out and tagged out” before anyone performs repairs on the machine.

LA

If the employee performing repairs to the machine is issued

NG

ER DO OP NO ER T AT E

NY

a lock and key, the employee shall not share the lock or key with other employees until all repair procedures are complete and the machine is ready to put back into service.

DA

SA

The following steps shall be performed in the sequence listed when the equipment is to be either locked-out or tagged-out for repair.

2-22

CA13082119

Shop Manual - June 2013

Shop Safety

SY195/205/215/225C9 Crawler Hydraulic Excavator

Locking out of service 1. Notify all employees who may be potentially affected by the repair process on the machine.

DANGER

2. Secure the machine in a safe position. If equipped, set the parking brake or hydraulic lock lever in the PARK or LOCKED position.

A

RI C

CA13082120

TI N

4. Be sure all employees involved in the repairs have installed there lock on the power source before performing any repairs. Once an employee has completed there repair procedure, they must remove there lock and not access the machine in any manor.

When this is not being used, keep it in the storage compartment.

AM E

3. Identify, remove or disconnect all power or energy sources and be sure to install a Lockout/Tagout device on them. If the machine is equipped with a Maintenance Alert Tag, attach this tag to the machine controls.

DO NOT OPERATE

LA

Returning to service

NY

1. The authorized person who performed the Lock out/Tagout procedure shall check the area around the machine to ensure that no one is exposed to any hazard before startup.

SA

2. The authorized person who performed the Lock out/Tagout shall ensure that all guards have been reinstalled to their proper place, all tools and equipment have been removed and all locks are removed. 3. The authorized person who performed the Lock out/Tagout shall verify that all controls are in the neutral or “off” position and all personnel are aware of the time the machine will be back in service.

Shop Manual - June 2013

2-23

Shop Safety

SY195/205/215/225C9 Crawler Hydraulic Excavator

4. Remove the Lockout/Tagout equipment and any additional alert equipment and reenergize the machine for return to service.

RI C

TI N

2.2.31 Material Safety Data Sheets (MSDS)

AM E

Exposure to hazardous chemicals pose a serious danger if released or mishandled. Handling hazardous materials often releases substances that could pose a hazard. Temporary implication or possible residual injury may result unless proper precautions are observed while working with these materials. All workers involved in handling hazardous materials should use approved personal protective equipment and follow all environmental safety regulations.

A

2.2.30 Chemical hazard

Material Safety Data Sheet (MSDS) information relating to the materials the workers could be exposed to.

NY

LA

● MSDS data sheets provide both workers and emergency personnel with the proper procedures for handling or working with a particular substance. Information includes physical data, health effects, first aid, reactivity, storage, disposal and protective equipment required.

SA

● Be sure all personnel involved are familiar with all MSDS-related information as it relates to the hazardous materials they could be exposed to. Keep MSDS data sheets handy in site of all employees and emergency personnel where they can be easily accessed. ● Never handle hazardous materials without the proper MSDS information. Always verify the data on the MSDS sheet before handling any hazardous materials.

2-24

Shop Manual - June 2013

CA13082121

Shop Safety

SY195/205/215/225C9 Crawler Hydraulic Excavator

2.3 Precautions for sling work and giving signals

RI C

A

1. Only one appointed worker is allowed to give signals and co-workers must communicate with each other frequently. The appointed signal person must give specified signals clearly at a place where he is seen well from the operator's seat and where he can see the working condition easily. The signal person must always stand in front of the load and guide the operator safely. ● Do not stand under the load.

2. Check the slings before starting sling work. 3. Always wear gloves during sling work. (Wear leather gloves, if available.)

AM E

● Do not step on the load.

TI N

4. Measure the weight of the load by the eye and check its center of gravity.

LA

5. Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall.

NY

6. Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically.

SA

7. Limit the hanging angle to 60°, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook.

Shop Manual - June 2013

2-25

Shop Safety

19.6 2000

kN kg 18.6 1900

16.7 1700

13.7 1400

9.8 1000

30

60

90

4.9 500

A

9.8 1000

120

150

RI C

Hanging angle (Deg.)

ZX215-1000001

TI N

8. When installing wire ropes to an angular load, apply softeners to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping.

19.6 2000

AM E

When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120°. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150°, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.

Load capacity kN(kg)

SY195/205/215/225C9 Crawler Hydraulic Excavator

9. Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc.

LA

10. Apply wire ropes to the middle portion of the hook.

NY

● Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.

SA

11. Do not use twisted or kinked wire ropes. 12. When lifting up a load, observe the following.

100%

88%

79%

71%

41%

ZX215-1000002

2-26

Shop Manual - June 2013

Shop Safety

SY195/205/215/225C9 Crawler Hydraulic Excavator

● Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught.

RI C

A

● After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and softener.

● Do not lift up the load slantingly. 13. When lowering a load, observe the following.

TI N

● When lowering a load, stop it temporarily at 30 cm above the floor, and then lower it slowly.

AM E

● If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again.

● Check that the load is stable, and then remove the sling.

SA

NY

LA

● Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.

Shop Manual - June 2013

2-27

Shop Safety

SY195/205/215/225C9 Crawler Hydraulic Excavator

Selecting wire ropes Select adequate ropes as per the weight of parts to be hoisted, referring to the table below. Wire ropes (Standard “Z” twist ropes without galvanizing) Nominal Diameter of Rope

Allowable Load kN

Ton

10

9.8

1.0

11.5

13.7

1.4

12.5

15.7

14

21.6

16

27.5

18

35.5

20

43.1

22.4

54.9

30

98.1

40

176.5

18.0

274.6

28.0

392.2

40.0

RI C

A

mm

1.6 2.2

TI N

AM E

2.8

50

LA

60

CAUTION

SA

NY

● The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).

2-28

Shop Manual - June 2013

3.6 4.4 5.6 10.0

Shop Safety

SA

BLNY ANLA TI KN PAAM E G RI E CA

SY195/205/215/225C9 Crawler Hydraulic Excavator

Shop Manual - June 2013

2-29

SY195/205/215/225C9 Crawler Hydraulic Excavator

BSLAN AYNL AT K IN PAA M GERI E CA

Shop Safety

2-30

Shop Manual - June 2013

RI C

Specifications 3 Specifications

TI N

AM E

Dimensions .............................................................................................................. 3-3 Working Ranges ...................................................................................................... 3-4 Technical Specifications........................................................................................... 3-5 Weight Table ............................................................................................................ 3-8 Recommended Oil, Fuel and Coolant...................................................................... 3-9 Capacity Table ....................................................................................................... 3-10 Engine Performance Curve ....................................................................................3-11

SA

NY

LA

3.1 3.2 3.3 3.4 3.5 3.6 3.7

A

Specifications

SY195/205/215/225C9 Crawler Hydraulic Excavator

Shop Manual - June 2013

3-1

Specifications

SA

NY

LA

TI N

AM E

RI C

A

SY195/205/215/225C9 Crawler Hydraulic Excavator

3-2

WARNING

Read and understand all safety precautions and instructions in this manual before reading any other manuals provided with this machine and before operating or servicing the machine. Also read the safety information on machine decals before performing any operations. Failure to do so can cause machine damage, personal injury or death.

Shop Manual - June 2013

Specifications

SY195/205/215/225C9 Crawler Hydraulic Excavator

3 SPECIFICATIONS 3.1 Dimensions

A D

RI C

A

I

C

E

G

AM E

H F

Item

TI N

B

L

J K

CJ13032601-1

Unit: mm (ft, in)

SY195C-9

SY205C-9

SY215C-9

SY225C-9

Overall length (shipping)

9560 {31'4''}

9680 {31'9''}

9680 {31'9''}

9680 {31'9''}

B

Overall width

2800 {9'2''}

2800 {9'2''}

2980 {9'9''}

2980 {9'9''}

C

Overall height (Shipping)

3250 {10'8''}

3440 {11'3''}

3440 {11'3''}

3440 {11'3''}

D

Width (top)

2710 {8'11''}

2710 {8'11''}

2710 {8'11''}

2710 {8'11''}

E

Overall height (to cab roof)

2990 {9'10''}

2990 {9'10''}

2990 {9'10''}

2990 {9'10''}

F

Std. track shoe width

600 {1'12''}

600 {1'12''}

600 {1'12''}

600 {1'12''}

G

Track gauge

2200 {7'3''}

2200 {7'3''}

2380 {7'10''}

2380 {7'10''}

H

Min. ground clearance

440 {1'5''}

440 {1'5''}

440 {1'5''}

440 {1'5''}

Tail swing radius

2890 {9'6''}

2890 {9'6''}

2890 {9'6''}

2890 {9'6''}

J

SA

NY

LA

A

Length of track on ground

3260 {10'8''}

3355 {11'0''}

3445 {11'4''}

3640 {11'11''}

K

Track length

4060 {13'4''}

4160 {13'8''}

4250 {13'11''}

4445 {14'7''}

I

Shop Manual - June 2013

3-3

Specifications

SY195/205/215/225C9 Crawler Hydraulic Excavator

3.2 Working Ranges

RI C

A

f

a g

TI N

AM E

b

e

LA

d

SA

NY

c

SY195C-9

a

Max. cutting height

9410 {30'10''}

9570 {31'5''}

9570 {31'5''}

9570 {31'5''}

b

Max. dumping height

6490 {21'4''}

6700 {21'12''}

6700 {21'12''}

6700 {21'12''}

c

Max. digging depth

6410 {21'0''}

6600 {21'8''}

6600 {21'8''}

6600 {21'8''}

d

Max. vertical digging depth

5790 {18'12''}

5800 {19'0''}

5800 {19'0''}

5800 {19'0''}

e

Max. digging reach

9740 {31'11''}

9950 {32'8''}

9950 {32'8''}

9950 {32'8''}

f

Min. swing radius

3755 {12'4''}

3595 {12'12''}

3595 {12'12''}

3595 {12'12''}

g

Max. height at min. swing radius

7700 {25'3''}

7665 {25'2''}

7665 {25'2''}

7665 {25'2''}

Item

3-4

CJ13032602-1

Unit: mm (ft, in) SY205C-9

SY215C-9

SY225C-9

Shop Manual - June 2013

Specifications

SY195/205/215/225C9 Crawler Hydraulic Excavator

3.3 Technical Specifications



0.8

0.8

0.9

1.0

kg kN kN rpm km/h Deg. kPa

21000 135 109 11 5.4/3.3 35 47

mm L KW/rpm

LA

NY

Type Max. delivery Safety valve pressure Type x No. Control method

SA

Hydraulic Control Hydraumotor valve lic pump

Track shoe (each side)

SY225C-9

Travel motor Swing motor

Type Bore Rod diameter Stroke Hydraulic tank Hydraulic oil filter element Hydraulic oil cooler

A

21200 21800 22600 138 138 138 103 103 103 11 11 11 5.4/3.3 5.4/3.3 5.4/3.3 35 35 35 46 47 46 MITSUBISHI 6D34-TL 6-cylinder, 4-cycle, water-cooled, in-line, direct injection 6-Φ104mm×115mm 5.86 114 / 2050

N·m/rpm rpm rpm g/KWh

Carrier roller (each side) Track roller (each side)

SY215C-9

590 / 1400 2200±50 1000±10 210 24V/5.0 KW 24V/50A

TI N

Max. torque Max. speed at no load Min. speed at no load Min. fuel consumption Starting motor Alternator

Hydraulic cylinder

Hydraulic system

Undercarriage

Engine

Performance

Operating weight Max. bucket digging force Max. arm digging force Swing speed Travel speed (Hi/Lo) Gradeability Ground pressure Model Type No. of cylinders-bore x stroke Piston displacement Rated power

SY205C-9

RI C

Bucket capacity

SY195C-9

AM E

Machine model

L/min Mpa

2

2

2

2

7

7

8

9

45

46

47

49

KAWASAKI (Variable displacement piston type) 2×210 34.3 KMX15RB/B45201B ×1 Hydraulic 2 x KYB variable displacement piston type (with brake valve and parking brake) 1 x KAWASAKI angle type, piston type (swing brake controller) Double acting piston 120 (Boom), 135 (Arm), 115 (Bucket) 85 (Boom), 95 (Arm), 80 (Bucket) 1285 (Boom), 1490 (Arm), 1120 (Bucket) Closed type Tank return side Air-cooling type

Shop Manual - June 2013

3-5

Specifications

SY195/205/215/225C9 Crawler Hydraulic Excavator

Engine Item

Specification

Engine model

6D34TLE2A

Type

In-line 6-cylinder; water-cooled, 4-cycle diesel engine

Combustion chamber type

Direct injection OHV kW{PS}/rpm

114{155}/2050

Max. torque

N·m{kgf·m}/rpm

590{60}/1400

Bore×Stroke

mm

φ104×115

cm³{L}

5860{5.860}

AM E

Total displacement Compression ratio

18.2

Swing motor

KAWASAKI

Model Type

TI N

Producer

cm³/rev

Safety valve set pressure

MPa {Kg/cm³}

Rated engine speed

2050

MPa {Kg/cm³}

3.4 {34}

Item

Specification KMX15RB

SA

Model

Standard flow rate (equivalent to one pump) Maximum pressure Maximum pressure

25.5 {260}

rpm

NY

Brake release pressure

M5×180CHB-12A-51A/260 angle type, piston type (swing brake controller) 129.2

LA

Theoretical displacement

Control valve

RI C

Max. output power

300 L/min

When main relief valve is normal

34.3 MPa

When main relief valve is boosting

37.3 MPa

When port relief valve is normal

39.2 MPa

Working oil temperature

-20~90°C

Drained oil maximum pressure

0.3 MPa

3-6

A

Valve mechanism

Shop Manual - June 2013

Specifications

SY195/205/215/225C9 Crawler Hydraulic Excavator

Travel motor Maker

KYB

Model

kg

MAG-170VP-3400E Variable displacement piston type (w/ brake valve and parking brake) 275

cm³/rev

qxi

Large displacement q1

cm³/rev

130.4

Small displacement q2

cm³/rev

74.9

Equivalent displacement Motor displacement q

RI C

Weight

A

Type

Speed reduction rate i 2-speed switching Pilot pressure

60

Lo-Hi

Mpa

Hi-Lo

Mpa

> 1.96

N·m

398

L/min

228

Operating pressure

Mpa

33.34

Peak pressure

Mpa

within 44.1

Acting times (above 34.3Mpa and below 44.1Mpa)

times

< 1,200,000

Large flow

rpm

1679

Small flow

rpm

2861

Large flow

rpm

28

Small flow

rpm

47.7

KN·m

within 37

Motor shaft Swing speed

Output torque Input power

Normal

PS

Maximum

PS

within 210 (within 30 consecutive sec.)

Normal

Mpa

within 0.2

Momentary maximum

Mpa

within 0.5 (below 0.3 MHz)

SA

NY

Drain pressure

LA

Reducer

TI N

Operating displacement

AM E

Braking torque

> 6.86

Shop Manual - June 2013

3-7

Specifications

SY195/205/215/225C9 Crawler Hydraulic Excavator

3.4 Weight Table Unit: kg SY205C-9

SY215C-9

SY225C-9

Engine

520

520

520

520

Radiator assembly

80

80

80

80

Hydraulic tank assembly (w/o hydraulic oil)

148

148

148

148

Fuel tank assembly (w/o fuel)

126

126

126

126

Revolving frame

1770

1770

1770

Operator cab

360

360

Operator seat & control console

75

75

Counterweight

3900

3900

Hydraulic pump

120

120

Control valve

185

Swing reducer assembly

200

A

SY195C-9

RI C

Machine Model

1770 360

75

75

3900

3900

120

120

185

185

185

200

200

200

300×2

300×2

300×2

56

56

56

2280

2432

2746

2746

286 116×2 135×2 25.5×4 40×14

286 116×2 135×2 25.5×4 40×14

286 116×2 135×2 25.5×4 40×16

286 116×2 135×2 25.5×4 40×18

1568

1568

1590

1590

706

709

709

709

769

769

781

781

206×2

206×2

206×2

206×2

262

262

262

262

Bucket cylinder assembly

188

188

188

188

Linkage

68

68

68

68

Rocker

22×2

22×2

22×2

22×2

Final drive assembly

300×2

Center swivel joint

56

Boom assembly Arm assembly

NY

Bucket assembly

LA

Swing bearing Idler Tensioning device Carrier roller Track roller

TI N

Track frame

Boom cylinder assembly

SA

Arm cylinder assembly

3-8

AM E

360

Shop Manual - June 2013

Specifications

SY195/205/215/225C9 Crawler Hydraulic Excavator

3.5 Recommended Oil, Fuel and Coolant

Reservoir

Fluid type

-22 -30

-4 -20

14 -10

Ambient temperature 32 50 68 0 10 20

86 30

104 40

122°F 50°C

SAE 10W Engine oil pan

RI C

SAE 10W-30

A

SAE 30

SAE 15W-40

AM E

Swing machinery Engine oil

case Idler

SAE 30

Track roller

LA

TI N

Carrier roller

Hydraulic system

SAE 10W SAE 10W-30 SAE 15W-40

L-HV32 Low-temp, wear-resistant hydraulic oil

NY

Hydraulic L-HM46 Wear-resistant hydraulic oil L-HM68 Wear-resistant hydra. oil

SA

oil

Fuel tank

Diesel fuel

ASTM D 975 No.2 GB252 Super-20 Diesel fuel GB252 Super-35 Diesel fuel

Grease fitting

Grease

Cooling system

Coolant

NLGI No.2 TEEC L35

Shop Manual - June 2013

3-9

Specifications

SY195/205/215/225C9 Crawler Hydraulic Excavator

● Machine oil above API CF-4 (no lower than APC CD) is recommended. ● Gear oil GL-5 is recommended. ● Obtain genuine oil from Sany Heavy Machine or its authorized dealers.

3.6 Capacity Table Final drive casing 5.5 {1.45}

Hydraulic system 239 {63.14}

Cooling system 22.5 {5.94}

SA

NY

LA

TI N

AM E

22 {5.81}

Swing mechanism casing 4.0 {1.06}

3-10

Shop Manual - June 2013

Fuel tank

340 {89.82}

RI C

Engine oil pan

A

Unit: L {US Gal}

Specifications

SY195/205/215/225C9 Crawler Hydraulic Excavator

3.7 Engine Performance Curve Testing condition: 1) Temperature: 298K, one standard atmospheric pressure. 2) No fan.

N·m Torque

RI C

500 400

Torque

A

600

300

AM E

kW 120

Power output

TI N

80

LA

Power output

100

NY

60

SA

40

240

20

Fuel consumption

230 220

Fuel consumption

g/kw·h

210

1000

1200

1400

1600

Engine speed min

1800

2000

-1

Shop Manual - June 2013

ZX215-1001003

3-11

SY195/205/215/225C9 Crawler Hydraulic Excavator

BSLAN AYNL AT K IN PAA ME G RI E CA

Specifications

3-12

Shop Manual - June 2013

Structure and Function

A

SY195/205/215/225C9 Crawler Hydraulic Excavator

RI C

Structure and Function 4 Structure and Function

SA

NY

LA

TI N

AM E

4.1 Engine and Cooling System .................................................................................... 4-5 4.1.1 Engine-related parts....................................................................................... 4-5 4.1.2 Radiator and intercooler................................................................................. 4-6 4.2 Power Train.............................................................................................................. 4-7 4.2.1 Power transmission system .......................................................................... 4-7 4.2.2 Final drive assembly ...................................................................................... 4-8 4.2.3 Swing machinery.......................................................................................... 4-12 4.2.4 Swing bearing .............................................................................................. 4-14 4.3 Undercarriage and Frame...................................................................................... 4-15 4.3.1 Track frame and recoil spring....................................................................... 4-15 4.3.2 Idler .............................................................................................................. 4-17 4.3.3 Carrier roller ................................................................................................. 4-19 4.3.4 Track roller ................................................................................................... 4-20 4.3.5 Track shoe ................................................................................................... 4-21 4.3.6 Triple grouser shoe ...................................................................................... 4-25 4.4 Hydraulic System, Part 1 ....................................................................................... 4-26 4.4.1 Hydraulic equipment layout.......................................................................... 4-26 4.4.2 Hydraulic tank and filter ............................................................................... 4-28 4.4.3 Hydraulic pump ................................................................................................... 4-29 4.4.4 Pilot pump .................................................................................................... 4-36 4.4.5 Regulator .................................................................................................... 4-37 4.4.5.1 Control mechanism makeup ............................................................... 4-39 4.4.5.2 Adjustment of the regulator ................................................................. 4-40 4.4.5.3 Operation ............................................................................................ 4-42 4.5 Hydraulic System, Part 2 ....................................................................................... 4-45 4.5.1 Control valve ................................................................................................ 4-45 Shop Manual - June 2013

4-1

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

SA

NY

LA

TI N

AM E

RI C

A

4.5.2 Operating principle ....................................................................................... 4-48 4.5.2.1 When spool is in neutral position ........................................................ 4-48 4.5.2.2 Travel .................................................................................................. 4-50 4.5.2.3 Arm...................................................................................................... 4-51 4.5.2.4 Boom................................................................................................... 4-56 4.5.2.5 Bucket ................................................................................................. 4-59 4.5.2.6 Swing .................................................................................................. 4-61 4.5.2.7 Option ................................................................................................. 4-63 4.5.2.8 Travel straight ..................................................................................... 4-64 4.5.2.9 Lock valve function ............................................................................. 4-65 4.5.2.10 Main relief valve function .................................................................. 4-67 4.5.2.11 Port relief valve function .................................................................... 4-68 4.5.3 Section view ................................................................................................. 4-72 4.6 Hydraulic System, Part 3 ....................................................................................... 4-83 4.6.1 Swing motor ................................................................................................. 4-83 4.6.2 Swing holding brake..................................................................................... 4-85 4.6.3 Relief valve portion ...................................................................................... 4-86 4.6.4 Reverse prevention valve ............................................................................ 4-88 4.6.4.1 Operation drawing............................................................................... 4-88 4.6.4.2 Explanatory drawing of effects ............................................................ 4-89 4.6.5 Center swivel joint ........................................................................................ 4-91 4.6.6 Travel motor ................................................................................................. 4-93 4.6.6.1 Operation of components.................................................................... 4-95 4.6.7 Valve control system .................................................................................. 4-107 4.6.8 Pilot valve.................................................................................................. 4-109 4.6.8.1 Work equipment and swing pilot valve.............................................. 4-109 4.6.8.2 Travel PPC valve ...............................................................................4-113 4.6.9 Solenoid valve.............................................................................................4-117 4.6.10 Accumulator ..............................................................................................4-118 4.6.11 Pilot oil filter ...............................................................................................4-119 4.6.12 Pump oil pressure sensor ........................................................................ 4-120 4.6.13 Hydraulic cylinder..................................................................................... 4-121 4.6.14 Work equipment ....................................................................................... 4-123 4.7 Air Conditioning System....................................................................................... 4-129 4.7.1 A/C components layout drawing ................................................................ 4-130 4.7.2 Control panel.............................................................................................. 4-131 4.7.3 Circuit diagram ........................................................................................... 4-132 4.7.4 Refrigeration principle ................................................................................ 4-134

4-2

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

SA

NY

LA

TI N

AM E

RI C

A

4.7.4.1 Refrigeration cycle diagram .............................................................. 4-134 4.7.4.2 Heating cycle diagram ...................................................................... 4-134 4.7.5 Compressor ............................................................................................... 4-135 4.7.6 Clutch ......................................................................................................... 4-137 4.7.8 Condenser ................................................................................................. 4-138 4.7.7 Expansion valve ......................................................................................... 4-138 4.7.9 Evaporator ................................................................................................. 4-139 4.7.10 Receiver tank ........................................................................................... 4-139 4.7.11 Pressure switch ........................................................................................ 4-140 4.7.12 Fresh air sensor ....................................................................................... 4-141 4.7.13 Refrigerant ............................................................................................... 4-141 4.7.14 Compressor oil ......................................................................................... 4-160 4.8 Engine Control ..................................................................................................... 4-161 4.8.1 System operation ...................................................................................... 4-162 4.8.2 Components............................................................................................... 4-163 4.8.2.1 Fuel control dial................................................................................. 4-163 4.8.2.2 Controller .......................................................................................... 4-165 4.9 Electrical Control System..................................................................................... 4-167 4.9.1 Control function .......................................................................................... 4-167 4.9.2 Machine control system diagram ............................................................... 4-168 4.9.3 Engine and pump composite control function ............................................ 4-170 4.9.4 Pump control function ................................................................................ 4-174 4.9.4.1 Electrical positive flow control ........................................................... 4-175 4.9.4.2 Constant power control ..................................................................... 4-178 4.9.5 Valve control function ................................................................................. 4-180 4.9.5.1 Bucket flow control ............................................................................ 4-181 4.9.5.2 Swing priority control......................................................................... 4-182 4.9.6 Duo travel speed control ............................................................................ 4-183 4.9.7 Engine preheating/overheating alarm ....................................................... 4-185 4.9.7.1 Engine preheating ............................................................................. 4-186 4.9.7.2 Engine overheating alarm ................................................................. 4-187 4.9.8 Engine oil under–pressure alarm ............................................................... 4-187 4.9.9 Auto deceleration/acceleration control ....................................................... 4-188 4.9.10 Engine speed calibration function ............................................................ 4-190 4.9.11 Electrical Components ............................................................................. 4-192 4.9.11.1 Pump pressure sensor .................................................................... 4-192 4.9.11.2 Pilot pressure sensor ...................................................................... 4-193 4.9.11.3 Engine speed sensor ...................................................................... 4-194

Shop Manual - June 2013

4-3

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

SA

NY

LA

TI N

AM E

RI C

A

4.9.11.4 Coolant temperature sensor............................................................ 4-195 4.9.11.5 Fuel level sensor ............................................................................. 4-196 4.9.11.6 Oil pressure switch .......................................................................... 4-197 4.10 Monitoring System ............................................................................................. 4-198 4.10.1 Machine monitor ...................................................................................... 4-199 4.10.2 Monitor functions...................................................................................... 4-200 4.10.3 Monitor operation ..................................................................................... 4-203

4-4

WARNING

Read and understand all safety precautions and instructions in this manual before reading any other manuals provided with this machine and before operating or servicing the machine. Also read the safety information on machine decals before performing any operations. Failure to do so can cause machine damage, personal injury or death.

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4 STRUCTURE AND FUNCTION 4.1 Engine and Cooling System

LA

TI N

AM E

RI C

A

4.1.1 Engine-related parts

Fan

3)

SA

1)

2

NY

1

4)

Start motor

5)

Rubber damper assembly

6)

Rear engine mount

7)

Muffler

2)

Front engine mount Fuel filter

3

4

5

6

7 ZX215-1002001

Specification Oil capacity: 22 L

Shop Manual - June 2013

4-5

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.1.2 Radiator and intercooler

2

3

1

A

4

RI C

5

6

AM E

7

TI N

8

LA

9

WX215-1204009G

Radiator outlet hose

2)

Radiator inlet hose

3)

Radiator

4)

Intercooler air intake

5)

Reserve tank

Aluminum pipe, belt-type radiator

6)

Intercooler

7)

Intercooler air outlet

8)

Fan guard

Radiator and oil cooler in parallel connection; intercooler in series connection with radiator and oil cooler.

9)

Radiator cap

SA

NY

1)

Specifications Radiator assembly: ZH860×385×1050-S70Y75Z20Q/SY015

Reservoir capacity: 8.9 L (2.35 US gal) Engine coolant capacity: 9.5L (2.51 US gal)

4-6

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.2 Power Train 4.2.1 Power transmission system 2

1

5

6

7

8

9

10

SA

NY

LA

4

TI N

AM E

RI C

A

3

ZX215-1002003

1)

Swing motor

6)

Accumulator

2)

Swing reducer

7)

Control valve

3)

Swing bearing

8)

Final drive AS

4)

Idler

9)

Hydraulic pump

5)

Central swivel joint

10) Engine

Shop Manual - June 2013

4-7

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.2.2 Final drive assembly Final drive AS (KYB)

1

3

2

4

19

17

73±3.6 N·m

205±10 N·m

RI C

A

5

AM E

59±4.9 N·m

18

TI N 11

8

157±8 N·m 16

NY

6 7

LA

12

20

10

9 ZX215-1002004-1

SA

13

14

15 ZX215-1002005

4-8

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

1)

Cylinder GP

9)

2)

Shaft

10) No. 2 planetary gear (No. of teeth: 36)

3)

Gear hub (No. of teeth: 85)

11) Seal ring

4)

No. 2 planetary carrier

12) Travel motor

5)

No. 1 planetary carrier

13) Fill port

6)

No. 1 planetary gear (No. of teeth: 36)

14) Level port

7)

No. 1 sun gear (No. of teeth: 12)

15) Drain port

8)

End cover

A

No. 2 sun gear (No. of teeth: 19)

RI C

Specifications Reduction ratio:

No.

AM E

( (12+85) /12) × ( (19+85) /19) ) -1= 43.246

Criteria

Check item

Standard clearance

Clearance limit

0.13 – 0.47

1.00

Backlash between No. 2 sun gear and No.2 planetary gear

17

Backlash between No. 1 planetary gear and gear hub

0.17 – 0.57

1.10

18

Backlash between No. 1 sun gear and No.1 planetary gear

0.14 – 0.46

1.00

Backlash between No. 2 planetary gear and gear hub

Backlash between No. 1 planetary carrier and No. 2 sun gear

Replace

Replace

0.16 – 0.56

1.10

0.38 – 0.66

1.00

SA

NY

20

LA

19

TI N

16

Remedy

Shop Manual - June 2013

4-9

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Final drive AS (Daewoo)

22

A

6

25 26

14 15

3 9 13 12 8

27

TI N

30

5

18

27

17

1 32

20

19

7

16

WX215-1204010G

13) Planetary gear shaft

25) Seal ring

14) Sun gear

26) O-ring

15) Snap ring

27) Thrust washer

16) Planetary gear

28) Thrust washer

17) Needle bearing

29) Thrust plate

18) Drive gear

30) Gear carrier

Planetary gear shaft

19) Spring pin

31) Gasket

8)

Planetary gear

20) End cover

32) O-ring

9)

Thrust washer

21) Socket head bolt

33) O-ring

10) Spring pin

22) Radial thrust ball bearing

34) Fill port

11) Needle bearing

23) O-ring

35) Level port

12) Floating bush

24) Plug

36) Drain port

O-ring

2)

Mandrel

3)

Float seal

4)

Gear carrier

5)

Hub

6)

Spacer

7)

4-10

SA

NY

LA

1)

21

28

11

9 31

24

29

4 10

2

AM E

23

33

RI C

22 3

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.2.3 Swing machinery

9

A

20 19

RI C

8 7

AM E

59~74 Nm

6 5

21 22 10 23 24 11

LA

3

TI N

4

12 25 26 13 27

NY

2 1

SA

14 15

16 17 18 28 ZX215-1002007

Shop Manual - June 2013

4-11

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Plug

11) No. 2 planetary gear GP

2)

Oil seal

12) No. 2 planetary gear (No. of teeth:17)

3)

Self-aligning bearing

13) Spring pin

4)

Ring gear (No. of teeth:52)

14) Swing reducer screw plug

5)

No. 2 planetary carrier

15) Grease fitting

6)

No. 1 planetary carrier

16) Self-aligning bearing

7)

No. 2 sun gear (No. of teeth: 16)

17) Bearing sealing

8)

No. 1 sun gear (No. of teeth:14)

18) Swing pinion

9)

Swing motor

19) Dipstick 20) Oil filling pipe

RI C

10) No. 1 planetary gear (No. of teeth:18) Specifications

AM E

Reduction ratio: (14+25) /14× (16+25) /14= 20.04

22

Standard clearance

Clearance limit

0.18 – 0.28



0.16 – 0.50

1.00

TI N

21

Criteria

Check item Backlash between swing motor shaft and No. 1 sun gear Backlash between No. 1 sun gear and No.1 planetary gear

LA

No.

A

1)

Backlash between No. 1 planetary gear and ring gear

0.18 – 0.59

1.10

24

Backlash between No. 1 planetary carrier and No. 2 sun gear

0.39 – 0.71

1.20

25

Backlash between No. 2 sun gear and No.2 planetary gear

0.16 – 0.50

0.90

Backlash between No. 2 planetary gear and ring gear

0.18 – 0.59

1.00

27

Backlash between No. 2 planetary carrier and swing pinion

0.07 – 0.23



28

Backlash between swing pinion and swing bearing

0.22 – 1.32

2.00

4-12

SA

26

NY

23

Shop Manual - June 2013

Unit: mm Remedy Replace

Replace

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.2.4 Swing bearing b

a

A

A

RI C

A

AM E

1

2

LA

TI N

3

549±50 Nm

549±50 Nm

2) 3)

ZX215-1002008

Swing bearing inner race (Teeth: 91)

Specifications

SA

1)

NY

A-A

Ball

Reduction ratio: 91/13= 7

Swing bearing outer race

Amount of filled grease: 13±1 Kg

a. Inner race soft zone S position b. Outer race soft zone S position

Unit: mm

Check item Axial clearance of bearing (when mounted on chassis)

Criteria

Remedy

Standard clearance

Clearance limit

0.5~1.6

3.2

Shop Manual - June 2013

Replace

4-13

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.3 Undercarriage and Frame 4.3.1 Track frame and recoil spring

2

3

4

AM E

RI C

A

1

7

5

10

9

LA

11

6

TI N

8

X

SA

NY

X

1)

Idler

2)

Track frame

3)

Carrier roller

4)

Sprocket

5)

Track roller

6)

Track shoe

7)

Center guard

8)

Front guard

4-14

ZX215-1002009

● Dimension and number of track rollers may vary depending on the machine model, but the basic structure is the same. Model

Q'ty (One side)

SY195C9

7

SY205C9

7

SY215C9

8

SY225C9

9

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Standard track shoe Model

SY195C9

SY205C9

SY215C9

SY225C9

600

600

600

600

Link pitch(mm)

190

190

190

190

Q'ty (One side)

45

46

47

49

Check item

9

Vertical width of idler guide

10

Criteria

Standard size Tolerance

Horizontal width of idler guide

107





Idler support

105





Track frame

250





Idler support

247





Standard size

Recoil spring

466

Build-up welding or replace

Installation load

Free length

Installation load

157.9 kN {16112 kg}

545

133.9 kN

Replace

SA

NY

LA

598 x 247

Remedy

Repair limit

TI N

11

Free length Installation x Outside length diameter

Unit: mm

Repair limit

Track frame

AM E

No.

RI C

A

Item Shoe width(mm)

Shop Manual - June 2013

4-15

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.3.2 Idler

5 6 4

A

3

8

2

SA

NY

LA

TI N

1

AM E

157~255 Nm

RI C

7

W13081901

4-16

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Unit: mm Check item

Criteria

1

Outside diameter of protrusion

2

Remedy Repair limit

560



Outside diameter of tread

520

508

3

Thickness of tread

30

24

4

Difference of tread

20

26

5

Total width

164



6

Width of tread

39.5



7

Diameter of shaft

8

Clearance between bushing and support (Sum of clearance at both sides)

65



Clearance limit

Replace



SA

NY

LA

TI N

AM E

Standard clearance 0.5~1.0

Build-up welding or replace

RI C

Standard size

A

No.

Shop Manual - June 2013

4-17

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.3.3 Carrier roller

3

A

5

AM E

RI C

8

7

2

1

No.

Check item

LA

TI N

6

4

ZX215-1002011

Unit: mm

Criteria

Remedy

Standard size

Repair limit

165



Outside diameter of tread

140

130

3

Width of tread

44



4

Thickness of tread

41.5

34

5

Width of flange

18



6

Clearance between shaft and bushing

Outside diameter of flange

2

7

8

4-18

SA

NY

1

Interference between roller and bushing Axial clearance of roller

Tolerance

Standard size

Shaft

50



Hole

Standard clearance

Clearance limit







Tolerance

Standard size

Shaft

Hole

57





Standard Interferinterference ence limit —



Standard clearance

Clearance limit

0.44 – 0.76



Shop Manual - June 2013

Replace

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.3.4 Track roller 9

A

3

8

1

RI C

2

AM E

549±59 Nm

7

5

6

Check item

LA

No.

TI N

4 W13081902

Unit: mm Criteria

Remedy

Standard clearance

Repair limit

193



160

148

Thickness of tread

46.5

40.5

4

Total width

237



5

Width of tread

46.5



6

Width of flange

32



7

Inside width

80

8

Diameter of shaft

65



9

Clearance between bushing and collar

Standard clearance

Clearance limit

0.5 – 1.0



Outside diameter of flange

2

Outside diameter of tread

3

SA

NY

1

Shop Manual - June 2013

Build-up welding or replace

Replace

4-19

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.3.5 Track shoe

A

1

AM E

RI C

4

19

21 15

23

TI N

7

11

12

20

LA

10

24

22

SA

9

4-20

5 14

2

3

8

13

NY

6

17

16

18

Shop Manual - June 2013

W13100801

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Unit: mm Criteria

Link pitch

2

Outside diameter of bushing

3

Thickness of bushing metal

4

Link height

Standard size

Repair limit

190

193

Standard size

Repair limit

59.45

53.7

10.75

5.75

Standard size

Repair limit

105

98

5 6

Shoe bolt pitch

69 Link

Overall width Tread width Regular

12

Protrusion of bushing

13

Overall length of pin

14

Overall length of bushing

15

Thickness of spacer

NY

38

2.7

Master

2.7

Regular

3.7

Master

0.0

Regular

207

Master

209

Regular

136

Master

128.5

Adjust or replace



Bushing

88.2 – 245 kN {9 – 25 ton}

Regular pin

127.4 – 274.4 kN {13 – 28 ton}

Master pin

78.4 – 147 kN {8 – 15 ton}



SA

18

Press-fitting force

40

TI N

Protrusion of pin

LA

11

82.57

AM E

Inside width

10

17

Repair or replace

119.57

8

16

Reverse or replace

155.57

7 9

Remedy

A

1

Check item

RI C

No.

Shop Manual - June 2013

4-21

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Unit: mm Check item

Criteria Tightening torque (Nm {kgm})

b. Master link

21

22

23

59.45

Interference between regular pin and link Clearance between regular pin and bushing

Interference between master pin and link

38.25 Standard size 38.25 Standard size

Clearance between master pin and bushing

Tolerance Shaft 0 -0.05 0 -0.04

38.25

Standard size 38.25

Shaft

Hole

0 0.8 -0.04 0.5 Tolerance

Shaft -0.08 -0.11

Hole -0.23 -0.29

Tolerance

Shaft

Hole

-0.5 -0.7

1 0.5

SA 4-22

Hole -0.25 -0.32 –0.23 –0.29

Tolerance

NY

24

Interference between bushing and link

LA

20

Standard size

A

Shoe bolt

Triple grouser 750±22.5 120±10 shoe {62.5±2.3} Retighten Tightening torque Retightening angle Lower limit torque (Nm {kgm}) (°) (Nm {kgm}) — — —

TI N

19

Retightening angle (°)

Standard interference 0.20 – 0.32 0.19 – 0.29

AM E

a. Regular link

Remedy

RI C

No.

Shop Manual - June 2013

Standard clearance 0.50 – 0.84

Standard interference 0.12 – 0.21 Standard clearance 1 – 1.7

Adjust or replace

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.3.6 Triple grouser shoe

1

6

4

AM E

3

RI C

8

1

Height

2

Thickness

3 4

Length of base

5 7

Thickness

2

ZX215 1002014

Unit: mm Remedy

Standard size

Repair limit

26

16 10 29.5 22

Build-up welding or replace

20.5 17 18

Standard size

Repair limit

36

26

SA

8

Length at tip

NY

6

Criteria

TI N

Check item

LA

No.

7

A

5

Shop Manual - June 2013

4-23

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.4 Hydraulic System, Part 1

2)

Arm cylinder

3)

Boom cylinder

4)

Hydraulic tank

5)

Hydraulic oil filter

6)

Control valve

7)

Hydraulic pump

8)

Radiator

9)

Accumulator

RI C

Bucket cylinder

AM E

1)

A

4.4.1 Hydraulic equipment layout

10) Left travel motor 11) Right travel motor 12) Swing motor 13) Lockout lever

1

TI N

14) Left pilot valve 15) Center swivel joint 16) Right pilot valve

LA

17) Travel pilot valve 18) Solenoid valve assembly

18A. Pilot lockout solenoid valve

18B. Boom priority solenoid valve

NY

18C. Bucket confluence solenoid valve 18D. Swing priority solenoid valve

SA

18E. Hi/Lo travel speed solenoid valve

4-24

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

3

5

6

7

8

LA

TI N

AM E

4

RI C

A

2

A

SA

NY

9

10 11 12 13 14 15 17

A 18A

16

18B

18C

18D 18E

18 W13081903

Shop Manual - June 2013

4-25

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.4.2 Hydraulic tank and filter

2

4

5

6

TI N

3

AM E

RI C

A

1

A

SA

NY

LA

A

7

A-A ZX215-1002017

1)

Hydraulic tank

Specifications

2)

Level gauge

3)

Oil filler cap

Tank capacity: 239 L (63 US gal) Available capacity: 172 L (45.5 US gal)

4)

Return oil filter element

5)

Bypass valve

6)

Breather valve

7)

Oil-suction filter element

Breather valve Filter fineness: 10μm Ambient temperature: -20~100°C Set pressure: Air inlet side: 0.005MPa Air outlet side: 0.05MPa

4-26

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.4.3 Hydraulic pump Type: K3V112DTP1N9R PH1

PH2

a2 {36N·m}

A1

A2

RI C

A

a1 {36N·m}

a5 {16N·m}

TI N

AM E

a4 {36N·m}

Clockwise

B3

DR1{170N·m}

Psv2

5

LA

B1

DR2{170N·m} a3 {36N·m}

SA

NY

4

A3 DR3{170N·m} 3

2

DR4{170N·m} 1

ZX215-1002018

Shop Manual - June 2013

4-27

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Outline ● This pump consists of 2 variable capacity swash plate plunger pumps, 2 regulators, and 1 pilot gear pump. NOTE: For the location of the hydraulic pump on the machine, see “Hydraulic equipment layout” on page 4-24. F. pump main pressure detection port

1)

Front pump

a2:

R. pump main pressure detection port

2)

Rear pump

a3:

F. pump regulator pressure detection port

3)

Pilot gear pump

a4:

Adjustor control pressure detection port

4)

Front pump regulator

a5:

Pilot gear pump output pressure detection port

5)

Rear pump regulator

PH1:

F. pump pressure sensor assembly port

PH2:

R. pump pressure sensor assembly port

A1:

F. pump delivery port

A2:

R. pump delivery port

A3:

Pilot gear pump delivery port

Psv2: R. pump regulator control port F. pump drain plug

Dr2:

R. pump drain plug

Dr3:

Air bleeder

Dr4:

Drain plug

B1:

Pump suction port

B3:

Pilot gear pump oil suction port

SA

NY

LA

Dr1:

4-28

RI C

AM E

TI N

Psv1: F. pump regulator control port

Shop Manual - June 2013

A

a1:

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

2

3

13

6

7

14

8

9

16

10

RI C

A

15

5

1)

Front shaft

2)

Min. delivery adjusting screw

3)

Front casing

4)

Swash plate

5)

Slipper

6)

Plunger

7)

Cylinder block

8)

Valve plate

9)

TI N

4

AM E

1

12

11 ZX215-1002019

End cover

10) Rear shaft 11) Rear casing

LA

12) Gear pump 13) Piston 14) Max. delivery adjusting screw 15) Gear shaft

SA

NY

16) Driving pin

Shop Manual - June 2013

4-29

Structure and Function

6

13

7

8

RI C

A

B

SY195/205/215/225C9 Crawler Hydraulic Excavator

18

4

A

5

AM E

1

17

TI N

Function

LA

● The torque of the engine is transmitted to the pump shaft (1), and drives cylinder block (7) to rotate. At the same time, nine plungers (6) slide along the thrust plate (8). Plunger (6) moves back and forth inside cylinder block (7) and pressurized oil is sucked and discharged alternatively.

SA

NY

● It is possible to change the discharge amount by changing the swash plate angle.

4-30

Shop Manual - June 2013

18

ZX215-1002020

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Structure ● Cylinder block (7) is supported to shaft (1) by spline (17). ● Shaft (1) is supported by front and rear bearings (18).

A

● Tip of plunger (6) is shaped as a concave ball and slipper (5) is caulked to it to form one unit.

● Swash plate (4) conducts high pressure oil to cylinder surface (B), and forms a static pressure bearing when it slides.

AM E

● Swash plate (4) has flat surface (A), and slipper (5) is always pressed against this surface while sliding in a circular movement.

RI C

● Plunger (6) and slipper (5) constitute the spherical bearing.

TI N

● Plunger (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7).

LA

● Cylinder block (7) seals the pressurized oil to thrust plate (8) and carries out relative rotation.

NY

● This surface is designed so that the oil pressure balance is maintained at a suitable level.

SA

● The oil inside the respective cylinder chambers of cylinder block (7) is sucked in and discharged through thrust plate (8).

Shop Manual - June 2013

4-31

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Operation of pump ● Cylinder block (7) rotates together with shaft (1), and slipper (5) slides on flat surface (A).

4

7 A

a

A

X B

ZX215-1002021

● (a) is named the swash plate angle.

● With central line (X) of swash plate (4) at a swash plate angle (a) in relation to the axial direction of cylinder block (7), flat surface (A) acts as a cam in relation to slipper (5).

5

AM E

4

6

A

F

a

TI N

● In this way, plunger (6) slides on the inside of cylinder block (7), so a difference between volumes (E) and (F) is created inside cylinder block (7).

5

RI C

● When this happens, swash plate (4) moves along cylindrical surface (B), so angle (a) between central line (X) of swash plate (4) and the axial direction of cylinder block (7) changes.

1

X

E

7

ZX215-1002022

LA

● A single plunger sucks and discharges the oil by the amount (F) – (E).

NY

● As cylinder block (7) rotates and the volume of chamber (E) becomes smaller, the pressurized oil is discharged.

SA

● On the other hand, the volume of chamber (F) grows larger and, in this process, the oil is sucked. ● As central line (X) of swash plate (4) overlaps the axial direction of cylinder block (7) (swash plate angle (a) = 0), the difference between volumes (E) and (F) inside cylinder block (7)becomes 0. ● Suction and discharging of pressurized oil is not carried out in this state. Namely pumping action is not performed. (In reality, however, the swash plate angle is not set to 0)

4-32

Shop Manual - June 2013

F

E 4

7 ZX215-1002023

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Control of delivery ● If swash plate angle (a) becomes larger, the difference between volumes (E) and (F) becomes larger and pump delivery (Q) increases.

13 16

F

● Piston (13) carries out linear alternating motion under the control of the adjustor.

RI C

a

E

ZX215-1002024

AM E

4

SA

NY

LA

TI N

● This linear motion is transmitted to swash plate (4) via drive pin (16). The sliding of the swash plate changes the swash plate angle and changes the discharge amount of the main pump.

A

● Piston (13) is used for changing swash plate angle (a).

Shop Manual - June 2013

4-33

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.4.4 Pilot pump NOTE: For the location of the pilot pump on the machine, see “Hydraulic equipment layout” on page 4-24.

433

710

354

700

351

RI C

A

435

434 310

AM E

355

732

311

307

307: Valve stem 308: Valve base

434

850

466

725

361: Body 433: Screw 434: Screw 435: screw

NY

309: Retainer 310: Spring

308

LA

309

TI N

312

466: Plug

312: Nut

700: Washer

SA

311: Adjusting screw 351: Body

710: O-ring

353: Gear shaft

725: O-ring

354: Gear shaft

732: O-ring

355: Filter element

850: Washer

Function ● The engine actuates the main pump and the drive shaft of the pilot pump through the transmission case, and drives the pilot pump through gear engagement.

4-34

Shop Manual - June 2013

435

361

353 ZX215-1002025

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.4.5 Regulator (KR3G-0E11-AV) NOTE: Both the front pump and the rear pump are equipped with a regulator. For the location of the hydraulic pump, see “Hydraulic equipment layout” on page 4-24.

A

079

418

PSV

B 624

627

646

897

415

AM E

KDRDE5C-1

A

325

a

408

RI C

SKY5P - 17 - S

496

496

924 801

755 466

402 656

643

407

A

733

631

TI N

(KDRDE5K)

651 652 733

PSV

Part No.

a

887

543

755

756

708

545

611

541

A-A

Tightening torTue

LA

731

724

601

614

402, 407 408 415

Name plate and s/n Tightening torTue

N‡m

M6

12

M8

29

M5

6.9

466

G1/4

16

496

NPTF1/16

8.8

614

G1/4

36

801

M10

29

418

NY

Thread size

Type s/n G-OE11-V

Direction B

SA

Hydraulic schematic diagram

ZX225-1102002

Shop Manual - June 2013

4-35

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Category

Part No.

Part name

Q’ty

C

924

Hexagon socket head locating screw

1

/

897

Pin

1

/

887

Pin

1

D

801

Hexagon nut

1

D

756

O-ring

2

D

755

O-ring

2

D

733

O-ring

2

D

731

O-ring

1

D

724

O-ring

5

D

708

O-ring

1

/

656

Cover plate

1

/

652

Spool valve

1

/

651

Sleeve

/

646

Guide spring

/

643

Pilot plunger

/

631

Pf pilot sleeve

/

627

Adjusting roller

1

/

624

Spring seat

1

/

614

Plug

/

611

Feedback lever

1

/

601

Casing

1

/

545

Ball

2

/

543

Stopper

2

/

541

Valve seat

2

C

496

Embedded plug

9

466

VIP plug

1

418

Hex socket head bolt

2

JIS B 1176 M5-12

415

Hex socket head bolt

6

JIS B 1176 M8-50

408

Hex socket head bolt

1

JIS B 1176 M6-40

407

Hex socket head bolt

4

JIS B 1176 M6-30

D

402

Hex socket head bolt

4

JIS B 1176 M6-16

/

325

Valve body

1

B

079

Sol proportional reducing valve

1

B



Regulator assembly

1

D D D

B: /: C: D: 4-36

AM E

RI C

A

JIS B 1181 N-M10

LA

TI N

1

NY

D

SA

C

Remark

1

1

1

1

Assembly obtainable at the dealers (individual parts not purchasable) Individual components included in assemblies of category B Parts obtainable at the dealers Parts obtainable on the market Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Function ● The regulator controls the pump discharge amount according to the command signal pressure, keeping the driving power of the pump lower than the engine output. a

2

3

RI C

A

1

AM E

● Pumps 1 and 2 are both equipped with a regulator. Key components of the regulator include a solenoid proportional pressure reducing valve (1), a positive flow regulator (2), a servo reversing valve (3) and a servo piston (4). The regulator opens and shuts the oil circuit of the servo piston (3) and changes the tilting angle of the hydraulic tank according to various command signal pressure so as to control the pump discharge amount.

PSV

4 ZX225-1102003

TI N

4.4.5.1 Control mechanism makeup Current control

SA

NY

LA

● The inclination (output delivery amount) of the pump can be controlled freely by changing of the command current I flowing into the solenoid proportional pressure reducing valve. This regulator applies positive flow control (positive control), through which output delivery amount Q changes according to the increase of command current. Necessary current for corresponding operation can be input through this control mechanism. The pump only delivers necessary oil amount and wastes no useless power.

Shop Manual - June 2013

4-37

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.4.5.2 Adjustment of the regulator

806

532

548 531

808

954

531: Inclination pin 532: Servo piston

PSV

806: Retaining nut 808: Retaining nut

LA

548: Feedback pin

ZX215-1002028

SKY5P - 17 - S

KDRDE5C-1

TI N

AM E

RI C

A

953

924

NY

953: Adjusting screw 954: Adjusting screw

SA

● It is possible to adjust the maximum and minimum flow by the adjusting screws (953, 954) in the pump block side. Flow control features can be adjusted with the hexagon socket head locating screw (924) on the regulator.

4-38

Shop Manual - June 2013

ZX225-1102004

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Maximum flow adjustment (pump block side)

RI C

A

Output flow Q

● Loosen the hexagon nut (808), and tighten (or loosen) hexagon socket head locating screw (954). No control features except the maximum flow changes.

NY

LA

● Loosen the hexagon nut (806), and tighten (or loosen) the hexagon socket head locating screw (953). Though this action is the same as the adjustment of maximum flow and all the other control features do not change, power required under maximum output pressure (overflow) is likely to increase if over-tightened. Be careful in this case.

ZX215-1002033

Output flow Q

TI N

Minimum flow adjustment (pump block side)

AM E

Command current I

SA

Command current I ZX215-1002034

Shop Manual - June 2013

4-39

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

RI C

A

● After hexagon nut (810) is loosened, tighten (or loosen) the hexagon socket head locating screw (924) to carry out adjustment. When the hexagon socket head locating screw (924) is being tightened, the control diagram (as shown) will move to the right.

Output flow Q

Flow control feature adjustment

Command current I

AM E

ZX215-1002037

Flow control

NY

LA

● The output flow of the pump can be controlled by the command current I, as shown.

Output flow Q

TI N

4.4.5.3 Operation

Command current I

SA

ZX215-1002030

4-40

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Action of increasing flow rate

627 646

643

801 924

P1

611 532

A

808

806 953

A

954 P1

Tilt angle large

TI N

● Since feedback lever (611) is integrated with the servo piston and valve sleeve (651), if servo piston (632) moves to the left, feedback lever swings with point A as the pivot. In this way, valve sleeve moves to the right.

651 652

RI C

● As spool valve (652) moves to the right, because port cl and tank port are interconnected, pressure of the large diameter portion of the servo piston is released and servo piston (532) moves to the left via the output pressure P1 in the shall diameter portion. The inclination becomes larger.

079

AM E

● When command current I increases, the solenoid proportional pressure reducing valve secondary pressure P2 will increase, and the spool valve (652) will move the right with the help of the guide piston (643). When a relative balance between the rightward hydraulic force and the spring force of guide spring (646) is achieved, spool valve (652) stops moving.

ZX225-1102005

PSV

a

NY

LA

● Through this movement, the opening portion between the spool and the valve block is closed slowly. The servo piston stops moving when the opening portion is completely closed.

SA

ZX225-1102006

Shop Manual - June 2013

4-41

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Action of reducing flow rate

651 652 627 646

643

801 924

P1

611 532

A

808

806 953

A

954

RI C

P1

Tilt angle small

ZX225-1102007

PSV

a

NY

LA

TI N

● As servo piston (532) moves to the right, the feedback lever swings with point A as the pivot and the valve sleeve moves to the left. Through this movement, the opening portion between the spool and the valve block is slowly closed. The servo piston stops moving when the opening portion is completely closed.

079

AM E

● When command current I decreases, the solenoid proportional pressure reducing valve secondary pressure P2 will decrease, and guide piston (643) will move to the left. However, as spool valve (652) moves, output pressure P1 is introduced into the large diameter chamber of the servo piston via the port cl. On the other hand, output pressure P1 is introduced into the small diameter chamber of the servo piston and servo piston moves to the right via are difference. The inclination becomes smaller.

ZX225-1102008

SA

Adjustment value of the regulator Type of regulator

KR3G-0E11-AV

-1

Rotating speed (min )

Adjustment of max. flow Adjustment of min. flow

4-42

2050 Adjusting screw (954) screw-in (rotation)

+1/4

Flow rate change (L/min)

-5.9

Adjusting screw (953) screw-in (rotation)

+1/4

Flow rate change (L/min)

+4.7

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.5 Hydraulic System, Part 2 4.5.1 Control valve NOTE: For the location of the control valve on the machine, see “Hydraulic equipment layout” on page 4-24. XBp2

XAa1

BaR

A

(XAo)

RI C

XAa2

BoR BkR

Psp

BbR

XBtr

XAs

AM E

XAb1

Dr2

XBtL

(PTa)

XBtr Dr3

PnA2

TI N

Dr6

Dr7

Pz

PX

AtL

PbL

LA

Pns

TRAVEL LEFT

BUCKET

XAk ARM2

SA

XBa2

Aa(Rod)

Ak(Head)

Atr

TRAVEL RIGHT

SWING

Dr1

Bb(Rod)

XBs BOOM2

SWING PRIORITY

AbR OPTION

PCk XBk Bk(Rod)

AkR

(Bo)

Dr3

(BYPASS CUT 1)

DR3

XAb2 (XBo)

ARM1

AoR PCV1

AaR

R2

PaL

As

XAtr

BtL

NY

XBb1

BOOM1

Btr

MR

Py

TRAVEL STRAIGHT

XAtL

Bs

PG

XBa1 (XBp1)

Ba(Head)

Ab(Head)

(Ao) P1

P2

R1

R1

ZX225-1102009

Shop Manual - June 2013

4-43

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

XBp2: Bypass cut spool pilot port (P2 side)

XBtr : R. travel (forward) pilot port

XAb2: Boom confluence (UP) pilot pressure

(XAo): (Option pilot port)

Psp:

Swing priority pilot port

(XBo): (Option pilot port)

R1:

Return port

XAk:

Bucket (DIG) pilot port

R2:

Oil feed port

XBk:

Bucket (DUMP) pilot port

Atr:

R. travel motor port (reverse)

XAb1: Boom 1 (UP) pilot port

Btr:

R. travel motor port (forward)

XBb1: Boom 2 (DOWN) pilot port

(Ao):

Option

XAa2: Arm 2 (OUT) pilot port

(Bo):

Option

XBa2: Arm 2 (IN) pilot port

Ak:

Bucket cylinder head end port (DIG)

XAtL: L. travel (reverse) pilot port

Bk:

Bucket cylinder rod end port (DUMP)

XBtL: L. travel (forward) pilot port

Ab:

Boom cylinder head end port (UP)

XAs:

Swing (left) pilot port

Bb:

Boom cylinder rod end port (DOWN)

XBs:

Swing (right) pilot port

AtL:

XAa1: Arm 1 (OUT) pilot port

BtL:

XBa:

Arm 1 (IN) pilot port

As:

Dr1:

Drain port

Bs:

Px:

Work equipment signal port

Aa:

Py:

Travel signal port

Pz:

L. travel motor port (reverse) L. travel motor port (forward) Swing motor port (left swing) Swing motor port (right swing)

Arm cylinder rod end port (OUT) Arm cylinder head end port (IN)

Main relief valve boosting pressure

P1:

Pump port (P1 side)

PG:

Pilot pressure resource port

P2:

Pump port (P2 side)

Pns:

Swing logic control valve pilot port

MR:

Main relief valve

PCK: Bucket (DIG) stroke limit pilot port

AR:

Arm regeneration check valve

PnA2: Arm 2 logic control valve pilot port

AbR:

Port relief valve

Dr2:

Drain port

BbR:

Port relief valve

Dr3:

Drain port

AkR:

Port relief valve

Dr6:

Drain port

BkR:

Port relief valve

Dr7:

Drain port

AoR:

Port relief valve

Pal:

Lock valve pilot port (arm rod end)

BoR:

Port relief valve

Lock valve pilot port (boom head end)

AaR:

Port relief valve

BaR:

Port relief valve

PbL:

NY

LA

Ba:

SA

TI N

AM E

RI C

A

XAtr : R. travel (reverse) pilot port

(XBp1):Bypass cut spool pilot port (P1 side)

NOTE: For more technical information about the control valve, see “Control valve” on page 3-6.

4-44

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Hydraulic circuit diagram (with bucket confluence function)

(P3)

P2

R1

(P0)

P1

PG

d1 ĭ0.7

d3 ĭ0.7

d2 ĭ0.7

CMR2

MR

CMR1 XBtr

TRAVEL R

Pz

(PTa)

TRAVEL STRAIGHT

XAtr Atr Btr

XBs

RI C

LCs 4-ĭ2.1

XAs As Bs Pns

C2

AM E

SWING PRIORITY

A

CP1

Dr2 Dr6

SWING

Px

CPG

Psp

Py

TRAVEL L

XBtl XAtl Btl Atl Dr1

LCb

BOOM2XAb2

XBb1

BOOM1

XAb1 AbR

Bb (ROD)

BbR

TI N

CCb

Ab (HEAD) HVb PbL

LCk

LCo

(XBo) (XAo)

AoR

(Ao) (Bo)

AR Dr3

LA

OPTION

PCk XBk

(ROD) Bk Ak (HEAD)

BkR

AkR

BoR

LCa

2-ĭ1.0 2-ĭ2.0

LCAP2

PnA2 Dr7

LCAT2

XAa1

XBa2

NY

ARM1

BUCKET

XAk

ARM2

XAa2

XBa1 (HEAD) Ba

AaR

SA

BaR

BYPASS CUT

Aa (ROD)

CCo HVa CCk

PaL

(XBp1) R2

XBp2 (P5)

ZX225-1102010

Shop Manual - June 2013

4-45

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.5.2 Operating principle 4.5.2.1 When spool is in neutral position [Main circuit]

AM E

RI C

A

● Working oil supplied from the hydraulic pump (Rear) flows in through pump port P2 and is introduced into the main passage (3). It passes the neutral bypass (2) (neutral M-shaped spool mechanism) of the spools of R travel (301), swing (305), boom confluence (boom 2: 307), option (309), arm 1 (302), and flows back into the working oil tank via return port (R1).

SA

NY

LA

TI N

● When all the spools are in neutral position, working oil supplied from the hydraulic pump (Front) flows in through pump port P1 and is introduced into the main passage (1). It passes the neutral bypass (2) (neutral M-shaped spool mechanism) of the spools of straight travel (308), L. travel (301), boom 1 (303), bucket (304) and arm 2 (306), and flows back into the working oil tank via return port (R1).

4-46

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

(2)

(1)

XAtL

XBtL

XBb1

XAbL

PCk

RI C

XAk

A

(PTa)

X8k XAa2

AM E

XBa2

CCo CCk P2

XBtr

Psp

R1

LA

XAs

(P3)

TI N

(3)

(XAo)

XAa1

(2)

XAtr

XBs

XAb2

(XBo)

NY

XBa1 (XBp1)

SA

XBp2

ZX225-1102011

Shop Manual - June 2013

4-47

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.5.2.2 Travel

● When pressure at pilot port XBtL for left travel spool (301) rises, neutral bypass (2) at boom 1 side is closed, and working oil supplied from the hydraulic pump (front) is introduced into the left travel motor via port Btl.

● On the other hand, return oil from the left and right travel motor passes the left (right) travel spool via port Atl (Atr), and returns to working oil tank via return port (R1).

A

[Main circuit]

RI C

● When the left or right travel spool is switched, the side bypass circuit is closed and pressure at port Py (travel signal port) rises.

● Likewise, when pressure at port XBtr for the right travel spool (301) rises, neutral bypass (2) at arm 1 side is closed, and working oil supplied from the hydraulic pump (rear) is introduced into the right travel motor via port Btr.

● The principle is the same when travel on the opposite side is operated (when pressure at pilot port XAtr and XAtl rises).

AM E

[Pilot circuit]

XBtr

Atr

Btr

SA

NY

LA

TI N

XAtr

Travel motor ZX225-1102012

4-48

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.5.2.3 Arm (1) Arm OUT [Pilot circuit]

● Return oil from the arm cylinder head end (H) via port Ba flows into the tank circuit of arm 1 and arm 2, and returns to working oil tank via tank port (R1).

SA

NY

LA

TI N

● When arm OUT is operated, pilot pressure oil is supplied into port XAa1 and port XAa2. When pilot pressure oil is applied at the two sides of port XAa1 and port XAa2, arm 1 spool and arm 2 spool are switched to the left as shown in the illustration. As a result, working oil from P2 is introduced into neutral bypass (2) via main passage (3). Neutral bypass is cut off by switching arm 1 spool (302). Therefore, working oil in the parallel passage pushes open the cone valve (511) of the check valve, and flows into the arm 1 spool (302) via the U passage. Then, it flows into the periphery of arm 1 spool (302) and arm 2 spool (306) and is supplied into the arm cylinder rod end (R) via port As.

AM E

[Main circuit]

RI C

A

● When the arm 2 spool (306) is switched, the side path is closed and pressure at port Px (work equipment signal port) rises.

● On the other hand, working oil from port P1 is introduced into neutral bypass (2) via main passage (1). Neutral bypass is cut off by switching the arm 2 spool (306). Therefore, working oil in the parallel passage pushes open the logic cone valve (256-101) of the arm 2 logic valve GP, and working oil from neutral bypass pushes open the cone valve (511) of the check valve and flows into the arm 2 spool (306) via the U passage. Then, it merges with port As via the inner passage of arm 2 spool (306) and is supplied into the arm cylinder rod end (R).

Shop Manual - June 2013

4-49

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

R

256-101

511

TI N

AM E

Aa

RI C

A

H

XAa2

SA

NY

LA

XAa1

Ba 511 ZX225-1102013

4-50

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

(2) Arm IN from neutral bypass pushes open the cone valve (511) of the check valve and flows into the arm 2 spool (306) via the U passage. Then, it merges with port Ba via the inner passage of arm 2 spool (306) and is supplied into the arm cylinder head end (H).

[Pilot circuit]

A

● If the pressure at the arm cylinder head end and in the U passage rises, arm regeneration check valve spool (257-211) switches to the left. And, at the same time, the back pressure of the cone valve (302317) in the spool is closed. Therefore, arm regeneration function is released and return oil from the arm cylinder rod end (R) flows into the spool via the hole (a) on the periphery of arm 1 spool (302). Then, it flows into arm regeneration check valve set (257) via hole (c) on the periphery of arm 1 spool (302), and returns to the working oil tank via tank port R1.

LA

TI N

● When arm In is operated, pilot pressure oil is supplied to port XBa1 and port XBa2. When pilot pressure oil is applied at the two sides of port XBa1 and port XBa2, arm 1 spool and arm 2 spool is switched to the left. As a result, working oil from P2 is introduced into the neutral bypass (2) via main passage (3). Neutral bypass is cut off by switching arm 1 spool (302). Therefore, working oil flown into the parallel passage pushes open the cone valve (511) of the check valve and flows into the arm 1 spool (302) via the U passage. Then, it flows into the periphery of arm 1 spool (302) and is supplied into the arm cylinder head end (H) via port Ba.

RI C

[Main circuit]

● On the other hand, pressure of the return oil from the arm cylinder rod end (R) rises under the weight the arm, and the return oil returns to port Aa. Working oil that returns to port Aa flows into the inside of the valve spool via the holes on the periphery of the arm 1 spool (302), and pushes open the cone valve (302-317) in the spool only under light load. It merges with port Ba through the holes on the spool. This is called the regeneration function of the arm.

AM E

● When the arm 2 spool (306) is switched, the side path is closed and pressure at port Px (work equipment signal port) rises. At the same time, pressure oil is supplied to port PaL and the release signal of lock valve option set (252) is sent out.

SA

NY

● On the one hand, working oil from port P1 is introduced into neutral bypass (2) via main passage (1). Neutral bypass is cut off by switching the arm 2 spool (306). Therefore, working oil in the parallel passage pushes open the logic cone valve (256-101) of the arm 2 logic valve GP, and working oil

Shop Manual - June 2013

4-51

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

● Light load

Arm weight R

RI C

A

H

AM E

Aa

TI N

XBa2

LA

(302-317)

SA

NY

XBa1

(b) (a)

Ba ZX225-1102014

4-52

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

● When pressure at arm cylinder head end (H) rises

R

RI C

A

H

AM E

Aa

TI N

XBa2

LA

(302-317)

NY

XBa1

SA

(c)

(257-211)

(a)

Ba ZX225-1102015

Shop Manual - June 2013

4-53

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.5.2.4 Boom (1) Boom UP

● On the other hand, return oil from the boom cylinder rod end (H) via port Bb flows into the periphery of boom 1 spool (303) and returns to the working oil tank via tank port (R1).

SA

NY

LA

TI N

● When boom UP is operated, pilot pressure oil is supplied into port XAb1 and boom 1 spool (303) moves to the left. Working oil from port P1 is introduced into neutral bypass (2) via main passage (1). Neutral bypass is cut off by switching boom 1 spool (303). Therefore, working oil in the parallel passage pushes open the cone valve (511) of the check valve, and flows into the boom 1 spool (303) via the U passage. Then, it flows into the periphery of boom 1 spool (303) and is supplied into the boom cylinder head end (H) via port Ab.

A

[Main circuit]

RI C

● When the boom 1 spool (303) is switched, the side path is closed and pressure at port Px (work equipment signal port) rises.

● At the same time, pilot pressure oil is also supplied to port XAb2 and boom 2 spool (307) moves to the right. Working oil from port P2 is introduced into neutral bypass. Neutral bypass is cut off by switching the boom 2 spool (307). Therefore, working oil in the parallel passage flows into boom 2 spool (307) via the U passage. Then, it pushes open the cone valve (511) of the check valve and merges with port Ab and is supplied into the boom cylinder head end (H). This is called the boom confluence function.

AM E

[Pilot circuit]

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Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

H

R

Ab

AM E

RI C

Bb

A

511

511

ZX225-1102016

SA

NY

LA

TI N

XAb2

XAb1

Shop Manual - June 2013

4-55

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

(2) Boom DOWN passage. Then, it flows into the periphery of boom 1 spool (303) and is supplied into the boom cylinder rod end (R) via port Bb.

[Pilot circuit]

● On the other hand, return oil from the boom cylinder head end (H) passes the hole (a) and the periphery of boom 1 spool (303).

A

● When the boom 1 spool (303) is switched, the side path is closed and pressure at port Px (work equipment signal port) rises. At the same time, pressure oil is supplied to port PbL and the release signal of lock valve option set (252) is sent out.

RI C

LA

TI N

● When boom DOWN is operated, pilot pressure oil is supplied to port XBb1. Boom 1 spool (303) moves to the right. As a result, working oil from P1 is introduced into the neutral bypass (2) via main passage (1). Neutral bypass is cut off by switching boom 1 spool (303). Therefore, working oil flown into the parallel passage pushes open the cone valve (511) of the check valve and flows into the boom 1 spool (303) via the U

● Return oil pressure rises due to the self weight of the boom. Cone valve (303-317) in the spool is pushed to the right. Return oil flows to the outside of spool. The pressure oil is supplied into the boom cylinder rod end (R) as the working oil for boom DOWN operation. This is called the boom regeneration function. Part of the oil that flows into the inside passage of the spool via hole (a) returns to the working oil tank via hole (b).

AM E

[Main circuit]

H

R

Ab

Bb

SA

NY

511

XBb1

(b)

(a)

(303-317) ZX225-1102017

4-56

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.5.2.5 Bucket (1) Bucket DIG Then, it flows into the periphery of bucket spool (304) and is supplied into the bucket cylinder head end (H) via port Ak.

[Pilot circuit]

A

● When boom UP and bucket DIG are operated simultaneously, pilot pressure oil is supplied to port Pck. Therefore, the stroke of bucket spool is not limited at stroke end, but on any position halfway. As a result, bucket cylinder passage is throttled and working oil flows into boom 1 spool (303) via bucket spool (304). In this way, boom UP operation takes precedence.

TI N

● When bucket DIG is operated, pilot pressure oil is supplied into port XAk and bucket spool (304) moves to the right. Working oil from port P1 is introduced into neutral bypass (2) via main passage (1). Neutral bypass is cut off by switching bucket spool (304). Therefore, working oil in the parallel passage pushes open the cone valve (511) of the check valve, and flows into the bucket spool (304) via the U passage.

RI C

[Main circuit]

● On the other hand, return oil from the bucket cylinder rod end (R) flows in via port Bk. Then, it flows to oil tank port (R1) via the spool periphery and returns to working oil tank.

AM E

● When the bucket spool (304) is switched, the side path is closed and pressure at port Px (work equipment signal port) rises. At the same time, pressure oil is supplied at port XBp2.

R

Ak

Bk

SA

NY

LA

H

XAk

H

Pck

ZX225-1102018

Shop Manual - June 2013

4-57

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

(2) Bucket DUMP

[Main circuit]

● On the other hand, return oil from the bucket cylinder head end (H) flows in via port Ak. Then, it flows to oil tank port (R1) via the spool periphery and returns to working oil tank.

AM E

● When bucket DUMP is operated, pilot pressure oil is supplied into port XBk and bucket spool (304) moves to the left. Working oil from port P1 is introduced into neutral bypass (2) via main passage (1). Neu-

A

● When the bucket spool (304) is switched, the side path is closed and pressure at port Px (work equipment signal port) rises. At the same time, pressure oil is supplied at port XBp2.

tral bypass is cut off by switching bucket spool (304). Therefore, working oil in the parallel passage pushes open the cone valve (511) of the check valve, and flows into the bucket spool (304) via the U passage. Then, it flows into the periphery of bucket spool (304) and is supplied into the bucket cylinder rod end (R) via port Bk.

RI C

[Pilot circuit]

R

LA

Ak

TI N

H

Bk

SA

NY

XBk

ZX225-1102019

(3) Bucket confluence ● When bucket DIG is operated, pilot pressure oil is supplied into port XBp2 and the neutral bypass cutoff valve spool (310) is switched. Working oil from port P2 is introduced into neutral bypass (2) via main passage (3). Neutral bypass is cut off by

4-58

switching neutral bypass valve spool (310). Therefore, working oil pushes open the check valve, and interconnects with the U passage via the inside path, and converges with bucket spool (304).

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.5.2.6 Swing (1) Swing operation (305). Therefore, working oil in the parallel passage pushes open the logic cone valve (2540-101) of the swing logic valve GP, and flows into the swing spool (305) via the U passage. Then, it flows into the periphery of swing spool (305) and is supplied into the swing motor via port As (or Bs).

[Pilot circuit] ● When the swing spool (305) is switched, the side path is closed and pressure at port Px (work equipment signal port) rises.

RI C

XAs

LA

TI N

XBs

● On the other hand, return oil from the swing motor flows in via port Bs (or port As). Then, it flows into tank port (R1) via the spool periphery and returns to the working oil tank.

AM E

● When swing is operated, pilot pressure oil is supplied into port XAs (or XBs) and swing spool (305) is switched. Working oil from port P2 is introduced into neutral bypass (2) via main passage (3). Neutral bypass is cut off by switching swing spool

A

[Main circuit]

Bs

SA

NY

As

(254-101)

Swing motor ZX225-1102020

Shop Manual - June 2013

4-59

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

(2) Swing priority function [Pilot circuit] ● Pilot pressure oil is supplied to port Psp and swing priority spool (311) is switch.

Psp

SA

NY

LA

TI N

AM E

RI C

A

[Main circuit]

● Switch swing priority spool (311). The opening area of the swing priority reduces. As a result, working oil from arm 1 spool (302) flows into swing spool (305) and swing operation takes precedence.

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Shop Manual - June 2013

ZX225-1102021

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.5.2.7 Option Option spool is used to control optional work equipment attachment. (1) Operation (309). Therefore, working oil in the parallel passage pushes open the cone valve (511) of the check valve, and flows into the option spool (309) via the U passage. Then, it flows into the periphery of option spool (309) and is supplied into the optional equipment via port Ao (or Bo).

[Pilot circuit]

A

● When the option spool (309) is switched, the side path is closed and pressure at port Px (work equipment signal port) rises.

● On the other hand, return oil from the optional equipment flows in via port Bo (or port Ao). Then, it flows into tank port (R1) via the spool periphery and returns to the working oil tank.

AM E

● When option is operated, pilot pressure oil is supplied into port XAo (or XBo) and option spool (309) is switched. Working oil from port P2 is introduced into neutral bypass (2) via main passage (3). Neutral bypass is cut off by switching option spool

RI C

[Main circuit]

XAo

Ao

Bo

SA

NY

LA

TI N

XBo

ZX225-1102022

(2) Option confluence ● To achieve option confluence, pilot pressure oil is supplied into port XBp1 and the bypass cutoff valve spool (310) is switched. Working oil from port P1 is introduced into neutral bypass (2) via main passage (1).

Neutral bypass is cut off by switching bypass valve spool (310). Therefore, working oil pushes open the cone valve (514) of check valve, and converges with option spool (309) via the inside path and the U passage.

Shop Manual - June 2013

4-61

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.5.2.8 Travel straight

● The side path of right/left travel spool (301) and the side path of the swing spool (305) at the downflow side are closed.

● On the other hand, working oil from port P1 is supplied to the swing motor via port As. ● When oil pressure at port P2 is lower than that at port P1, part of the working oil form port P1 is supplied to port P2. In this way, sharp decrease of travel speed is averted.

P1

P2

PTa

SA

NY

LA

TI N

● Pilot oil from port PG is supplied to port PTa and straight travel spool (308) is switched.

A

[Pilot circuit]

● When straight travel spool (308) is switched, the right/left travel spool (301) are interconnected with port P2. The parallel passage of swing/boom 2/option/arm 1 circuit and boom 1/bucket/arm 2 circuit are interconnected with port P1. Therefore, working oil supplied from port P2 flows into port Atl and port Atr, and is supplied to the two travel motors equally.

RI C

The following case shows when travel spool (301) and swing spool (305) are operated simultaneously. (When pilot pressure oil is supplied to port XAtL, port XAtr and port Xas)

[Main circuit]

AM E

When travel spool (301) and other spool are operated simultaneously.

ZX225-1102023

4-62

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.5.2.9 Lock valve function

(1) Spool in neutral position ● The following shows when boom 1 spool (303) is in neutral position. (The same is with arm 2 spool (306))

A

252-511 252-541

LA

(b)

TI N

252-321

● At this position, working oil at the boom cylinder head end (H) flows in via hole (a) and flows out from hole (b) through the periphery of the lock valve option set spool (252-511), pressing the cone valve (513) against the valve seat of the valve block via hole (b). By this means, oil leakage is reduced.

RI C

● Likewise, lockout option set (252) is also installed between boom cylinder head end (H) and boom 2 spool (303) to reduce the internal leakage of he spool due to cylinder pressure.

● When boom 1 spool (303) is in neutral position, spool (252-511) in the lock valve option set is pressed against the valve seat of the valve sleeve (252-541) inside the lock valve option set, as shown in the illustration, via the spring force of spring (252321).

AM E

● The lock valve option set (252) is installed between the arm cylinder rod end (R) and arm 2 spool (302) and arm 2 spool (306). It is used to reduce the internal leakage of the spool due to cylinder pressure.

513

SA

NY

(a)

ZX225-1102024

Shop Manual - June 2013

4-63

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

(2) Boom DOWN operation

A

into spring chamber (RH). In addition, oil in the spring chamber (RH) flows into drain circuit via hole (b). In this way, the cone valve (513) is pushed up by the pressure at boom cylinder head end (H) and the function of the lock valve option set (252) is released.

252-511

(RH)

AM E

(b)

RI C

● When boom DOWN is operated, pilot pressure oil is supplied to port PbL and port XBb1. Spool (252-511) inside the lock valve option set moves to the top by via pilot pressure oil. Through the movement of spool (252-511) inside the lock valve option set, hole (a) is cutoff and working oil from boom cylinder head end (H) does not flow

513

(a)

LA

TI N

PbL

NY

XBb

SA

ZX225-1102025

(2) Boom UP operation ● When boom DOWN is operated, pilot pressure oil is supplied to port XAb1. The cone valve (513) is pushed ope by the oil from

4-64

boom 1 spool (303) and working oil flows into port Ab.

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.5.2.10 Main relief valve function

611

621

P

R

LA

TI N

541

● When pressure oil high than 3MPa is supplied to port Pz, this pressure oil pushes plunger (614) to the left. The set load of spring (621) is changed and pressure of the main relief valve rises.

AM E

● When pressure in passage (P) exceeds the elastic force of spring (621), cone valve (611) is pushed open. Therefore, working oil flows through the hole on valve sleeve (103) via the periphery of cone valve (611)

● Opening of cone valve (611) causes pressure in chamber (a) to drop and valve rod (512) is open. In this way, working oil in passage (P) flows into low-pressure path (R) directly.

A

● Working oil flows into chamber (a) from passage (P) via the hole of valve seat (541) and hole on valve rod (512). Valve rod (512) is pressed against valve seat (541), forming a tight seal.

and enters low-pressure path (R).

RI C

The main relief valve is installed on the valve block A (101). Its function is described below:

NY

Pz (a)

103

614

ZX225-1102026

SA

512

Shop Manual - June 2013

4-65

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.5.2.11 Port relief valve function The port relief valve is installed between the tank port and low-pressure path. In addition to the function as relief valve, it has also the function of anti-cavitation oil complement check valve. Its function is described below: (1) Relief valve function

AM E

RI C

A

● Working oil flows into chamber (B) via the hole (A) on plunger (301). Valve rod (511) is pressed against valve seat (541), and valve seat (541) is pressed onto the valve seat of the valve block, forming a tight seal.

B

TI N

A

P

511

NY

301

LA

R

ZX225-1102027

B

SA

A

541

P

301

R 511

4-66

541

Shop Manual - June 2013

ZX225-1102028

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

● When pressure in passage (P) exceeds the elastic force of spring (621), cone valve (611) is pushed open. Therefore, working oil flows through hole (C) via the periphery of cone valve (611) and enters low-pressure path (R).

RI C

A

C

AM E

P

R

621

ZX225-1102029

TI N

611

LA

C

SA

NY

P

R 611

621 ZX225-1102030

Shop Manual - June 2013

4-67

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

● Opening of cone valve (611) causes pressure in chamber (B) to drop and valve rod (511) is open. In this way, working oil in passage (P) flows into low-pressure path (R) directly.

RI C

A

B

R

P

ZX225-1102031

LA

B

611

TI N

511

AM E

P

511

611 ZX225-1102032

SA

NY

R

4-68

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

(2) Anti-cavitation oil complement check valve

AM E

RI C

A

● When negative pressure is formed in path (P), working oil is supplied from path (R). When pressure in path (R) gets higher than pressure in path (P), valve seat (541) moves to the right direction. Therefore, working oil is supplied from path (R) to path (P) via the periphery of valve seat (541) in order to prevent cavitation.

P

TI N

R 541

NY

LA

ZX225-1102033

SA

P

R 541 ZX225-1102034

Shop Manual - June 2013

4-69

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.5.3 Section view

B

273×10

A

153 (Po)

561

XAtr

HR

273×12

D

252 PnS 977 978×2

Dr8 E

TRAVEL L

XAtl

SWING

BOOM2

XAb2

E

XAk

XBo

OPTION

BUCKET

F

AM E

G

D BOOM1

XBbl

AbR

F

A

XBs

TRAVEL STRAIGHTC

RI C

C

TRAVEL R

AoR

AkR

XBa1

ARM1

XBa2

AR

(BYPASS CUT1) H BYPASS CUT2

(XBp1)

G

PnA2 Dr7

O

AaR

O 252

AaR

TI N

H

PCV1

ARM2

602

A

B

XBa2

(XBp1)

LA

Dr3

NY

View O-O

SA

274×4

Dr6

CCo

Pns

CCk

(P5)

PnA2

P

Dr7

P

210 561

153 (P5)

Viw P-P

XAa2 273×12 XBp2

XBk 273×10 PCk ZX225-1102035

4-70

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Section A-A, N-N N 101 159

541

542

543 166

A

550

RI C

(PTa)

N

AM E

XAtL

XBb1

XAbL

PCk

TI N

XAk

XBk XAa2

CCo

CCk

514 521 561 551

551 561 521

514

View A-A

SA

NY

LA

XBa2

XBtL

151 168 151 168

151

PB

168

156

2-156 View N-N

Shop Manual - June 2013

ZX225-1102036

4-71

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Section B-B

153

P2

(P3)

561

R1

975

102

A

975

XBtr

RI C

XAtr

AM E

XAs

Psp

975

XBs 975 XAb2

(XAo)

TI N

(XBo)

975 XAb1

975 XBa1

LA

975

NY

XBp2

SA

975

4-72

975

165

(XBp1)

975 165 View B-B

Shop Manual - June 2013

165 ZX225-1102037

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Section C-C (Travel right, travel straight)

154 164 TRAVEL RIGHT

201 336

TRAVEL STRAIGHT

201 336 332

XAtr

332

323

321

335

A

335

RI C

320

332

AM E

163 314 165

CP1

165 163

CMR2

NY

Btr

562 562

553 522 512 159

264 204

512

CMR1

SA

163

Pz

553

LA

561

163

308 601

522

511 521 551

261

Atr

TI N

163

332

MR

261

332

159 264 XBtr

(PTa) View C-C

204 164 154 ZX225-1102038

Shop Manual - June 2013

4-73

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Section D-D (Swing, travel left)

201 SWING

201 336

TRAVEL LEFT

XBs

336 332

XAtL

332 335

335 321

A

321

320

RI C

320

332

AM E

261 305 161 163 163

314

TI N

511 C2

521 551

LA

251

261

AtL

As 254

332

BtL

561

SA

165

NY

Bs

Dr2

264

XAs 204

XBtl

264 204

163

163

View D-D ZX225-1102039

4-74

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Section E-E, L-L (Boom 1, boom 2)

202

BOOM2

336 332

BOOM1 201 336 332

XBb1

XAb2

339 327

335 321

RI C

A

326

332 261

L

511

AM E

161 Dr1

521 CCb 551

332 261

L 158

PbL 523 CRb

TI N

165 307

LCb 551 561 Bb

NY

311

303

SA

163

511 521

LA

Xb2

551 561

161

552 561 513

561

163

320 602

264

261

602

332

XAb1

204

BbR

320 329

158

339 332 336 202

Psp SWING PRIORITY

View E-E

View L-L ZX225-1102040

Shop Manual - June 2013

4-75

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Section F-F (Option, bucket)

259 164 201

201

BUCKET

OPTION

336

336

332

(XBo)

332 335

A

335

321

321

RI C

320

AkR

332 261

163 209

(Ao)

163 511 521

511 521

LA

LCo 551 561

551 561 Bk

SA

971×4 209

NY

(Bo) 163 165

304

Ak

TI N

971×4 165 309 163

261

AM E

604

320 602 332

163

602

264 604

(XAo)

204 164

BkR XBk

BoR

154

264 206 211 561 258

PCk View F-F

4-76

Shop Manual - June 2013

ZX225-1102041

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Section G-G (Arm 1, arm 2)

201 201

336

336

332 XBa1

332 335

XBa2

335

321 320 257

Dr3

RI C

332

A

321

AR

261

AM E

L

163 165 162

TI N

152 165 162 152 302 511 521

LA

551 561

332 261 306 158

CRa

513 523 561 552 251

LCAT2

256 551 561

R2

NY

163

L

320

521

SA

511

165 163 264

264

602 BaR 205

XAa2

XAa1

204 View G-G ZX225-1102042

Shop Manual - June 2013

4-77

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Section H-H (Bypass cut 1, bypass cut 2)

169 162 152 158 154 164 152 162 162 152 164 154 158 152 162 164 154 169 612

PCV2

RI C

PCV1

310

203 333 331 372 373 337 331 262

AM E

XBp2

165

165

SA

NY

LA

TI N

View H-H

310

4-78

Shop Manual - June 2013

162 152

A

612

(XBp1)

163 262 331 337 373 372 331333 203

ZX225-1102043

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Mounting NO. torque (N·m)

Mounting NO. torque (N·m)

Part name

Q’ty

101

BLOCK, valve A

1

308

102

BLOCK, valve B

1

13~17

151

PLUG

34~39

152

220~250

Part name

Q’ty

1

3

310

SPOOL, bypass cut

2

PLUG

7

311

SPOOL, swing priority

1

153

PLUG

3

320

SPRING

9

69~78

154

PLUG

6

321

SPRING

8

7.4~9.8

156

PLUG, orifice

3

322

SPRING

1

7.5~10

158

PLUG

5

323

SPRING

1

10~14

159

PLUG

3

326

SPRING

1

161

O-RING

3

327

SPRING

1

162

O-RING

7

329

SPRING

1

163

O-RING

21

331

SPRING SEAT

4

164

O-RING

7

332

SPRING SEAT

22

165

O-RING

14

333

FLANGE SOCKET

2

166

O-RING

1

335

STOPPER

9

168

O-RING

3

336

FLANGE SOCKET

11

169

O-RING

2

337

STOPPER

2

201

COVER, spring

9

339

STOPPER

2

202

COVER, spring

2

372

SPRING

2

203

COVER, spring

2

373

SPRING

2

204

COVER, spool

7

511

VALVE, cone

8

205

COVER, spool

1

512

VALVE, cone

2

206

COVER, spool

1

513

VALVE, cone

2

RI C

AM E 16~18

TI N

LA

NY

A

309

SPOOL ASS’Y, travel straight SPOOL, option

16~18

1

FLANGE

2

514

VALVE, cone

2

210

PLATE

1

521

SPRING

10

211

PISTON

1

522

SPRING

2

49~65

251

2

523

SPRING

2

9.8~14

252

VALVE, logic control OPTION ASS’Y, lock valve VALVE GP, swing logic

2

541

BALL

1

1

542

SPRING SEAT

1

1

543

SPRING

1

1

25~29

550

PLUG

1

258

VALVE GP, arm 2 logic CHECK VALVE ASS’Y, arm regeneration PLUG

1

230~260

551

PLUG

11

259

PLUG

1

230~260

552

PLUG

2

261

O-RING

11

130~150

553

PLUG

2

SA

209

254 256 69~78

257

Shop Manual - June 2013

4-79

Structure and Function

Mounting NO. torque (N·m) 262

SY195/205/215/225C9 Crawler Hydraulic Excavator

Part name

Q’ty

O-RING

2

Mounting NO. torque (N·m) 561

264

O-RING

9

25~34

273

SCREW, hex, S,H,C

44

98~120

274

SCREW, hex, S,H,C

301 302

Q’ty

O-RING

17

562

O-RING

2

69~78

601

VALVE, main relief

1

4

69~78

602

VALVE, port relief

6

SPOOL, travel

2

120~140

604

VALVE, port relief

2

SPOOL ASS’Y, arm 1

1

69~78

612

PLUG

2

303 SPOOL ASS’Y, boom 1

1

49~65

971

SCREW, hex, S,H,C

8

304

SPOOL, bucket

1

140~180

975

SCREW, hex, S,H,C

10

305

SPOOL, swing

1

977

PLATE name

1

306

SPOOL, arm 2

1

978

PIN

2

307

SPOOL, boom 2

1

SA

NY

LA

TI N

AM E

RI C

A

Part name

4-80

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.6 Hydraulic System, Part 3 4.6.1 Swing motor

L

AM E

RI C

A

NOTE: For the location of the swing motor on the machine, see “Hydraulic equipment layout” on page 4-24.

SH

PB

TI N

IP

PG

PA

DR

LA

M

B

A

1

A: B:

SA

NY

2

ZX215-1002081

Main oil port

1. Relief valve

Main oil port

2. Reverse prevention valve

M: Oil complement port PA: Pressure detection port PB: Pressure detection port

For more technical information about the swing motor, see “Swing motor” on page 3-6.

DB: Lubricating port PG: Brake release port SH: Brake direction port L:

Oil level stick

IP: Gear oil feed port Shop Manual - June 2013

4-81

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

7

RI C

A

6

A 8

AM E

A-A

9

A

LA

4

TI N

5

10

11

NY

3

12

SA

2

13

1

ZX215-1002082

1)

Spacer

6)

Check valve spring

11) Plate

2)

Casing

7)

Check valve

12) Piston

3)

Disc

8)

Oil distribution plate

13) Drive shaft

4)

Brake spring

9)

Cylinder

5)

Shell

10) Brake piston

4-82

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.6.2 Swing holding brake ● Port PG is connected with the pilot gear pump directly, and a pressure of 3.9MPa is maintained.

A

M a

Pump

RI C

1

Main valve

7

PX PG

SH

ZX215-1002083

TI N

5

AM E

6

LA

● Port SH is connected with port PX of the main valve. Once any movement other than travel is applied on the main valve, pressure will be generated at port PX, and port PG is interconnected with chamber a beneath piston 7. The pressurized oil compresses brake spring (1) and pushes the brake piston up. Disc (5) is separated from plate (6), releasing the brake.

NY

M

a

SA

Pump

1 Main valve

7

PX PG

6 SH 5

ZX215-1002084

● Otherwise, no pressure is generated at port PX, and port PG is shut off from chamber a beneath piston (7). Brake piston (7) is pushed down by brake spring (1). Disc (5) and plate (6) are pushed together, and the brake is applied. Shop Manual - June 2013

4-83

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.6.3 Relief valve portion NOTE: For the location of the relief valve on the swing motor, see “Swing motor” on page 4-81. Structure ● The relief valve portion consists of relief valves (1) and (2), check valves (3) and (4).

RI C

SA

NY

LA

TI N

● In order to avoid the motor damage, the relief valve relieves the abnormally high pressure to port (M) from the motor outlet side (high-pressure side) of the motor.

AM E

● When the machine is in the swing holding mode, control valve (5) closes the motor outlet circuit, but the motor rotation continues due to inertial force. The motor output, therefore, is abnormally increased, resulting in motor damage.

A

Function

4-84

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Operation 1. When swing begins (suppose pressurized oil enters Port A)

From port M

1

2

● When the swing control lever is operated for right swing, pressurized oil from the pump is supplied to port (A) via control valve (5).

RI C

A

● The pressure on port (A) rises, the starting torque is generated in the motor, and the motor is activated.

3

● The pressurized oil from the outlet port of the motor passes from port (B) through the control valve (5) and returns to the tank.

C

A

AM E

2. When swing stops

4

● When the swing control lever is neutralized, the supply of pressurized oil from the pump to port (A) is cut off.

B

5 ZX215-1002085

TI N

From port M 1

2

LA

● The pressurized oil from the motor outlet can't return to the tank since the return circuit to the tank is closed from control valve (5). Thus, pressure at port (B) rises.

NY

● Swing resistance is generated on the motor and hence the brake starts working.

4

3

SA

● Pressurized oil will be relieved when the pressure on port (B) rises to the set pressure of relief valve (2). ● A high braking torque is applied on the motor, thereby stopping the motor.

C A

B 5 ZX215-1002086

● When relief valve (2) is being actuated, the relieved pressurized oil and the pressurized oil from port (M) are fed to port (B) via check valve (4). ● Above prevents cavitation on port (B).

Shop Manual - June 2013

4-85

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.6.4 Reverse prevention valve 4.6.4.1 Operation drawing NOTE: For the location of the reverse prevention valve on the swing motor, see “Swing motor” on page 4-81. T1

7

6

2

3

4

TI N

1

B

AM E

T2

RI C

A

A

5

LA

Swing motor

T

A

B

Swing control valve

1)

Valve body

2)

ZX215-1002087

Spool (B side)

Spool (A side)

6)

Spring (B side)

3)

Spring (A side)

7)

Plug

4)

Plug

4-86

SA

NY

5)

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.6.4.2 Explanatory drawing of effects

With reversal prevention valve :Without reversal prevention valve Reversal pressure

Containment pressure

Reversal pressure

RI C

Pressure MB

A

Pressure MA

1st reversal

Brake

Start

AM E

2nd reversal

Motor speed

Reversal

TI N

Time

Outline

LA

● Inertia of the swing body, the backlash and rigidity of the machinery system, and the compression of the hydraulic oil all may cause the machine to shake during swing operation. The reverse prevention valve is designed to reduce this effect. The valve contributes in preventing collapsing of load when the swing is stopped and also contributes in reducing cycle time (enhances the positioning performance, enabling you to proceed to the next work quicker than ever).

ZX215-1002088

A c e

D4 a D3

SA

NY

T

D1 d Notch D2 % b f 7 ZX215-1002089

Shop Manual - June 2013

4-87

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Operation 1. When port (B) brake pressure is generated ● Pressure (MB) is conducted to chamber (d) via the notch. The pressure compresses spring (6) by use of the difference in areas of circles (D1 > D2) of spool (5) and moves spring (6) to the left side. Port (B) and chamber (e) will be interconnected. Since pressure (A) is lower than the set pressure of spring (3), spool (2) does not move and the pressurized oil is stopped by spool (2). Thus the braking force is ensured.

$ T ' D '

RI C

A

F H

%

E I

AM E

' G Notch '

2. When motor is stopped

ZX215-1002090

A T

a 2

3

NY

LA

TI N

● The motor rotation is reversed by the closing pressure generated at port (B). (1st time: reverse rotation) Reversing pressure is generated on port (A). Pressure (A) is conducted to chamber (a), and spool (2) moves spring (3) to the right side, and A and B is interconnected. At this time, b is interconnected with f via the orifice on spool (5), and reversing pressure on port A is bypassed to port T, preventing the second reverse rotation.

T

B b f T ZX215-1002091

SA 4-88

5 d

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.6.5 Center swivel joint NOTE: For the location of the central swivel joint on the machine, see “Hydraulic equipment layout” on page 4-24. Z 8

13

9

10

6

11

F 4

D

AM E

C

RI C

12

5

H

A

7

B

A

3

LA

1

TI N

2

NY

H

H-H

G1

SA

F1

G D1

A1 B1 C1 Z ZX215-1002092

1)

Swing shaft

8)

Plug (ZG3/4)

2)

Dust seal

9)

Plug (ZG1/4)

3)

O-ring

10) Cover

4)

Swing body

11) Spacer

5)

Rotating seal φ100x5

12) Gasket

6)

Gasket

13) Gasket

7)

Retaining ring φ 90 Shop Manual - June 2013

4-89

Structure and Function

B:

From main valve BTR

C:

From main valve ATL

D:

From main valve ATR

A1:

To L. travel motor port (P1)

B2:

To R. travel motor port (P2)

C3:

To L. travel motor port (P2)

D4:

To R. travel motor port (P1)

G:

To swing motor port DB

G1:

From travel motor final drive assembly oil drain port (D1,D2)

F:

From solenoid valve port A2

F1:

To travel motor reducer Hi/Lo speed switching port (P)

RI C

From main valve BTL

SA

NY

LA

TI N

AM E

A:

A

SY195/205/215/225C9 Crawler Hydraulic Excavator

4-90

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.6.6 Travel motor Model: TM40VD-A-99/163-1

A

NOTE: For the location of the travel motor on the machine, see “Hydraulic equipment layout” on page 4-24.

RI C

D1 A P1

AM E

P

P2

B D2

P5

TI N

WX215-1204014G

Duo speed pilot hose port

P1:

Pressure detection port

P2:

Pressure detection port

P5:

Parking brake release port

NY

LA

Ps:

D1:

Drain port

D2:

Plug

A:

Main oil port

B:

Main oil port

Working condition

Gear ratio

SA

Reduction gear

Hydraulic motor

Speed 1

Speed 2

49.95

Theoretical output torque

(kgf.m)

Max. 4650

4535

2767

Theoretical output speed

(r.p.m)

Max. 60

28

45.9

Displacement

(cc/rev)

Max. 174.7

162.9

99.4

(kgf/cm2)

Max. 350

Theoretical speed

(r.p.m)

Max. 2800

Flow

(l/min)

250

(kgf/cm2)

20~70

(kgf.m)

Min. 50

(kgf/cm2)

8.2

Continuous pressure

Duo speed control pressure Braking torque Brake release pressure

350 1400

2294 228

1~3L/min (above 365) 15L/min (above 420)

Relief valve activation pressure

Shop Manual - June 2013

4-91

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Explosive view

37 46 44 22

34

20 6

23 24 14

25

8

29

10

31 32

52 51

2

4

58 57 59 13 16

53

1)

27

30

15

54 12 55 56

49

33

5

15 18 17

21

19 42

9 7 15 4

21

35

14

47 48

RI C

6

42

A

1 8

41

50

40

AM E

10

11 3

43

15

7

28 9 3

Flange, rear

16) Plug

2) H5 balance valve spool

17) Spool

3)

36

TI N

5

38

39 45 26

WX215-1204013G

46) Ball bearing

32) Spheric bush

47) Spring

18) Spring

33) Timing plate

48) Piston

Plug

19) Ball

34) Parking piston

49) Stopper

4)

D type block

20) Orifice

35) Spring

50) Pivot

5)

Check plug

21) O-ring

Check valve

22) Filter

36) C y l i n d e r b l o c k spring

51) Plunger

6) 7)

Spring

23) Name plate

37) Friction plate

53) Valve body

8)

Stop spring

24) Rivet

38) Spacer

54) Washer

9)

O-ring

25) Plug

39) Oil seal

55) O-ring

26) Drive shaft

40) O-ring

56) O-ring 57) Shim

12) Socket head bolt

27) P - t y p e s w a s h plate

41) O-ring 42) Parallel pin

58) Spring

13) O-ring

28) Cylinder block

43) Washer

59) Piston rod

14) Plug

29) Piston

44) Washer

15) Plug

30) Stopper

45) Ball bearing

NY

SA

10) O-ring

11) Parallel pin

4-92

LA

31) Baffle

Shop Manual - June 2013

52) Piston seal

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Model: MAG-170VP-3400E NOTE: For the location of the travel motor on the machine, see “Hydraulic equipment layout” on page 4-24.

Ps

Tin

Dr

1

P1

A

AM E

RI C

A

Pm1

Ps:

Duo speed pilot hose port

2

P2

B ZX215-1002132

A. Mounting surface with sprocket

LA

Pm1: Pressure detection port

Pp

TI N

Pm2

B. Mounting surface with undercarriage 1. Mounting hole with sprocket

Tin:

Motor case inner oil port

2. Mounting hole with undercarriage

Pp:

Brake release port

Dr:

Oil drain port

P1:

Main oil port

P2:

Main oil port

SA

NY

Pm2: Pressure detection port

NOTE: For more technical information about the travel motor, see “Travel motor” on page 3-7.

Shop Manual - June 2013

4-93

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Connected to sprocket

Mounted on the undercarriage 5

4

2-1

1-4

1-3

A

Piston motor shaft

AM E

RI C

1-5

1-6

1-2

3

2-4

2-3

4-94

2-2

2-6

2-5 ZX215-1002093

SA

NY

LA

TI N

1-1

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.6.6.1 Operation of components Counterbalance valve Function

● This valve can serve as a shuttle valve for high pressure selection to release the brake under its own pressure.

RI C AM E

● The counterbalance valve and the relief valve constitute the braking circuit. The braking circuit applies braking force onto the rotating motor and stops the motor gradually.

A

● When external load makes the rotating speed of the piston motor faster than the rated rotating speed of supplied delivery, this valve controls the speed of the motor and prevent over-speed of the motor in relation with the supplied delivery.

SA

NY

LA

TI N

● The structure of a standard counterbalance valve is shown as below. The following information describes the operating principle of a standard counterbalance valve.

Shop Manual - June 2013

4-95

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

A. Stopped state pressure is generated at port P1 and port P2. The motor is not rotating.

● When the main valve is neutralized (motor stopped), port M1 and port M2 are shut off by spool (1) and check valve (2) since no

RI C

A

8-1

8

8-2

Circuit C1

AM E

Circuit B Circuit C2

M2

M1

Orifice D1 Damper chamber A1

Orifice D3 Damper chamber A2

Spring chamber 1 P1

7-1

P2

3

4-1

2-1

1

2-2

4-2

5-2 ZX215-1002094

SA 4-96

6-2

7-2

NY

5-1

Spring chamber 2

LA

6-1

TI N

Orifice D4 Orifice D2

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

B. When the motor is activated damper chamber (A1) via orifice (4-1) and check valve (5-1). The force generated in this way pushes spring (7-2) on the other side and moves piston (1) to the right. At this time, return oil from port M2 passes through circuit of the notch on the periphery of piston (1), and through port P2 when pressure is generated at port M2, and enters the tank via the main valve finally. The motor is activated at this time.

AM E

RI C

A

● When hydraulic oil from the main pump enters port P1 of the counterbalance valve, spring (3) is pushed to the left by check valve (2-1), opening circuit C1. The hydraulic oil enters the piston motor via port M, trying to make the motor rotating. At the same time, return oil from the piston motor enters the counterbalance via port M2, but it is stopped by check valve (2-2). The output pressure of the main pump increases as a result, and the hydraulic oil works on the inside of spring chamber (1) and

8-1

TI N

8 8-2

Circuit C1

LA

M1

Orifice D1 Damper chamber A1

Circuit B Circuit C2 M2

Orifice D3 Damper chamber A2 Orifice D4

Orifice D2

NY

Spring chamber 2

Spring chamber 1

P2

P1

6-2

SA

6-1

7-2

7-1 5-1

3

4-1

2-1

1

2-2

4-2

5-2 ZX215-1002095

Shop Manual - June 2013

4-97

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

RI C AM E

SA

NY

LA

TI N

● When the engine runs at an excessively high speed because of external force applied on it, the motor may lose control. At this time, port P1 serves as the inlet side, and the pressure drops. Pressure in spring chamber 1 and damper chamber A1 also drop. As a result, pison (1) moves to the left under the force of spring (7-2), closing circuit B. Circuit at the suction side is also closed at the same time when the circuit at return side is closed. When circuit B is closed, pressure at port P1 rises due to hydraulic oil from the main pump, moving piston (10 to the right again. In this way, when external load generates pump effect, slight movement of piston (1) keep circuit B open. The rotation speed of the motor keeps in line with fuel supply of the main pump, and the motor will not lose control because of the vacuum in the hydraulic system.

A

C. Counterbalance function

4-98

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

D. Braking of motor braking force of motor rotation. When the pressure at port M2 reaches the set pressure of relief valve (8), cone valve (8-1) at port M1 overcomes the force of spring (82) and moves to the left, and hydraulic oil flows the port M1. In this way, the impacting force due to inertia at port M2 is under control, and vacuum at port M1 is avoided.

AM E

RI C

A

● The counterbalance valve and the relief valve forms the braking circuit. When the main valve is neutralized position, hydraulic oil from the main pump is cut off, and pressure at port P1 and P2 is the same. As a result, piston (1) moves to the neutral position, and the opening area of circuit B decreases. At the same time, because of the inertia of external force, the motor does not stop rotating (pump effect), and pressure at port M2 rises and serves as the

8-1

TI N

8 8-2

Circuit C1

Circuit B Circuit C2 M2

Orifice D3

LA

M1

Orifice D1 Damper chamber A1

Damper chamber A2 Orifice D4

Orifice D2

NY

Spring chamber 2

Spring chamber 1

P2

P1

6-2

SA

6-1

7-1

5-1

7-2 3

4-1

2-1

1

2-2

4-2

5-2 ZX215-1002096

Shop Manual - June 2013

4-99

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

E. Shuttle valve function for high pressure selection

A

ber E to release travel brake. In addition, piston (1) moves to neutral position, as shown in fig 5 when motor stops. Circuit D is closed and drain circuit F of motor body is connected. Hydraulic oil in travel braking cylinder chamber E is conducted to the drain circuit of motor body, and travel brake is applied.

RI C

● The counterbalance valve can function as a shuttle valve to release travel brake. When hydraulic oil is fed to port P1, piston (1) moves to the right, as shown in fig. 4. At this time, drain circuit F of motor body is cut off, and circuit D leading to cylinder chamber E for travel braking is connected. Hydraulic oil flows to circuit G via the orifice, and enters travel brake cylinder cham-

1

AM E

Circuit D Circuit D

Orifice

SA

NY

1

Circuit F Circuit D

Circuit F

TI N

Circuit G

Circuit G

LA

Circuit F Circuit D

Cylinder chamber E

ZX215-1002097

Circuit D Circuit D

Orifice Circuit G

Circuit F Circuit G Cylinder chamber E

ZX215-1002098

4-100

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Operation of parking brake

1) When travel begins ● As the travel lever is operated, pressurized oil from the pump activates counterbalance valve spool (10), opens the parking brake circuit, and flows to chamber A of brake piston (12). Pressurized oil overcomes the force of spring (11) and pushes piston (12) toward the left.

A RI C AM E

● Since the pushing force to plate (13) and disc (14) disappears, plate (13) is separated from disc (14) and the brake is released.

10

11

14

13 12

A

Travel control valve

M 22

ZX215-1002099

TI N

2) When travel stops

10

SA

NY

LA

● As the travel lever is placed in neutral, counterbalance valve spool (10) returns to the neutral position and closes the parking brake circuit. The pressurized oil in chamber (A) of brake piston (12) passes through the orifice of the brake piston and is drained to the motor case. Brake piston (12) is pushed to the right by spring (12). Plate (13) and disc (14) are pushed together, and the brake is applied. As brake piston (12) returns, flow of pressurized oil is reduced with slow return valve (22). The time delay will be set to activate the brake only after the machine has stopped.

Travel control valve

11

Shop Manual - June 2013

14

13 12

A

M 22

ZX215-1002100

4-101

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Brake valve operation ● The brake valve consists of suction safety valve (8A) and counterbalance valve (18). Functions and operations of respective components are described below.

Travel control valve PA

PB

18

RI C

A

8A

1) Counterbalance valve and check valve

MB

AM E

MA

ZX215-1002101

TI N

Function

SA

NY

LA

● When the machine is travels downhill, the weight of the machine tends to make the travel speed faster than the motor speed. If the machine travels with the engine at low speed, the motor may rotate at zero load, resulting in run away and inviting a very dangerous situation. These valves are used to avoid such a situation by controlling the machine to travel as per the engine speed (pump delivery).

Operation when pressurized oil is supplied

PA

PB

8B

8A

19

● Operating the travel lever conducts the pressurized oil from the control valve to port (PA). The pressurized oil opens suction safety valve (8A) and then flows to motor outlet port (MB) via motor inlet port (MA). The motor outlet side is closed by suction safety valve (8B) and spool (19), so the pressure at the supply side rises.

4-102

Travel control valve

Shop Manual - June 2013

MA

MB ZX215-1002102

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

● The pressurized oil on the supply side flows to chamber (S1) via orifice (E1) and orifice (E2) of the spool (19). As the pressure in chamber (S1) goes above the spool selector pressure, spool (19) is pushed toward the right. Port (MB) and port (PB) are connected, the motor outlet port side opens and the motor starts rotating.

Travel control valve

PB

PA

RI C

19

A

S1

MA

MB

Operation of brake during downhill travel

ZX215-1002103

Travel control valve

PB

PA

20

S1

19 MA

MB

E1 E2 ZX215-1002104

SA

NY

LA

TI N

● If the machine goes out of control while travelling downhill, the motor will be caused to rotate without load to decrease the inlet side oil pressure. Pressure in chamber (S1) is released via orifices (E1) and (E2). As the pressure in chamber (S1) goes below the spool selector pressure, spool (19) is returned to the left by spring (20) and outlet port (MB) is throttled. The pressure at the outlet port side rises, generating rotation resistance on the motor to prevent the machine from losing control. On the other hand, the spool moves to a position where the pressure on outlet port (MB) can be balanced against the machine's own weight and the inlet port pressure. Oil flow from the outlet circuit is reduced to ensure the travel speed corresponded to the pump delivery.

AM E

E1 E2

Shop Manual - June 2013

4-103

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

2) Safety valve Function

RI C AM E

Operation

A

● When the machine travel is stopped (or it is travelling downhill), the counterbalance valve closes the inlet and outlet circuits of the motor. Since the motor is rotated by inertial force, pressure in the motor outlet port side is abnormally increased, potentially resulting in damages on the motor and piping. The safety valve releases this abnormal pressure to the inlet port side of the motor in order to prevent damages to the equipment.

Travel control valve

1. When travel is stopped (or when travelling downhill) (Right swing)

20

TI N

● Reduction of the pressure at motor inlet (PA) decreases the pressure in chamber (S1). When it drops beyond the spool switching pressure, the spool is returned to the left by spring (20), reducing the pressure at outlet passage (B1). At this time, the motor continues rotating due to its inertial force, thus pressure on the outlet port (MB) is increased.

PB

PA

LA

S1

MA

MB

A1

NY

B1

ZX215-1002105

SA

● When the pressure rises above the set pressure of the suction safety valve (8A), the poppet opens. The pressurized oil passes through notch (A1) of spool (19) into chamber (MA) of the circuit at the opposite side. Spool

MB

MA ZX215-1002107

4-104

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

2. When starting travel (or when traveling at a constant speed)

Travel control valve

PB

PA

● As the travel lever is operated, the pressurized oil from the pump moves spool (19) toward right. The passage to the suction safety valve functions as a circuit which passes through notch (B2) of spool (19), producing large differential pressure. The pump pressure rises, providing a large tractional force to the valve.

8A

A

S1

RI C

19

MA

B2 ZX215-1002106

LA

TI N

● The structure of the relief valve is shown in the right figure. This valve is area difference and direct flow type. It has impact damping function during starting and braking.

MB

AM E

E1

3) Relief valve

8B

ZX215-1002108

NY

A. Operation principle and function

2-9-2

2-9-5

SA

● When the main valve makes the motor to start or brake, front pressure of cone valve (2-9-2) rises above the set pressure and the force of spring (2-9-5), and moves cone valve (2-9-2) to the right and off the valve seat. Pressurized oil in the front of cone valve (2-9-2) is bypassed to the low pressure side. The impact due to inertia energy at the high pressure side is put under control and vacuum is prevented from occurring at the low pressure side through bypassing pressurized oil to the low pressure side.

2-9-3

Shop Manual - June 2013

ZX215-1002109

4-105

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

B. Damping function Area S2

2-9-5

Spring chamber D

RI C

2-9-3 Area S1 2-9-9

A

2-9-2

LA

TI N

AM E

ZX215-1002110

SA

NY

Pressure

● When the relief valve begins to function, damping piston (2-9-9) moves to the left. As a result, low pressure is maintained in spring chamber D. At this time, the loaded area of cone valve (2-9-2) is S1, and it is much larger than the normal set loaded area S1-S2 of the relief valve. So, when damping piston (2-9-9) is moving, the functional pressure of relief valve is maintained at 1/3 of normal set pressure in order to absorb the impact at the high pressure circuit side due to inertia energy. When the movement of damping piston stops, pressure in spring chamber D rises. Pressure at both side of cone valve (2-9-2) is the same, and the relief valve is working at normal set pressure. In this way, the relief valve reduces the impact during motor start and brake by a two-stage action to provide excellent performance.

Damping method

Time ZX215-1002111

4-106

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.6.7 Valve control system

AM E

RI C

9

A

8

7 6 1

2

10

5

3

5

TI N

4

6

9

11

12

8

3

10

LA

13

4

7

NY

2

SA

11

1

12

Shop Manual - June 2013

ZX215-1002112

4-107

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Control lever position Travel PPC valve

(1) HOLD

2.

L. travel control lever

(2) Boom UP

3.

R. travel control lever

(3) Boom DOWN

4.

Right PPC valve

(4) Bucket DUMP

5.

Right joystick

(5) Bucket DIG

6.

Accumulator

(6) HOLD

7.

Transition block

(7) Arm IN

8.

Hydraulic pump

(8) Arm OUT

9.

Main control valve

(9) Right swing

RI C

A

1.

(10) Left swing

11. Left joystick

(11) Neutral

12. Left PPC valve

(12) Reverse travel

AM E

10. Solenoid valve

SA

NY

LA

TI N

(13) Forward travel

4-108

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.6.8 Pilot valve 4.6.8.1 Work equipment and swing pilot valve P3

P2

A T

2

3

RI C

A

P

P

AM E

1

4

P4

A

19~22Nm

SA

NY

LA

TI N

64~73.5Nm

P1

ZX215-1002113

P: P1: P2: P3: P4: T:

From pilot pump relief valve L.H. Pilot valve: Arm OUT L.H. Pilot valve: Arm IN L.H. Pilot valve: Swing LEFT L.H. Pilot valve: Swing RIGHT To tank

R.H. Pilot valve: Boom DOWN R.H. Pilot valve: Boom UP R.H Pilot valve: Bucket DIG R.H. Pilot valve: Bucket DUMP

Shop Manual - June 2013

4-109

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

6 7

AM E

RI C

8

A

5

4

9

TI N

3

A-A

ZX215-1002114

1)

Plunger

6)

Nut (for lever connection)

2)

SA

NY

1

LA

2

10

Metering spring

7)

Joint

3)

Centering spring

8)

Plate

4)

Piston

9)

Retainer

5)

Disc

10) Valve body

4-110

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Operation 1. When in neutral ● Ports (A) and (B) of the control valve and ports (P1) and (P2) of the pilot valve are connected to drain chamber (D) via orifice (f) in plunger (1).

D

2. Fine control (Neutral to fine control)

A

f

T

● When piston (4) is pushed by disc (5), retainer (9) is pushed, plunger (1) is also pushed by metering spring (2), and moves down.

AM E

P

Pilot pump

P1

M

A

P2

Control valve

M

TI N

● When orifice (f) is shut off from drain chamber (D), it is almost simultaneously interconnected to pump pressure chamber (PP). Pilot pressurized oil of the control pump is led to port (A) from port (P1) via orifice (f). When the pressure at port (P1) becomes higher, plunger (1) is pushed back and orifice (f) is shut off from pump pressure chamber (PP). At almost the same time, it is connected to drain chamber (D) to release the pressure at port (P1). As a result, plunger (1) moves up and down until the force of metering spring (2) is balanced with the pressure at port (P1).

RI C

1

B

LA

ZX215-1002115

f

T

1

SA

NY

● The relationship of the position of plunger (1) and body (10) [orifice (f) is in the middle between drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) contacts plunger (1). Metering spring (2) contracts in proportion to the stroke of the control lever. Pressure at port (P1) also rises in proportion to the stroke of the control lever. In this way, the control valve spool moves to a position where the pressure of chamber (A) (same as pressure at port (P1)) and the force of the return spring of the control valve spool are balanced.

D

P

Pilot pump

A

P1

M

P2

Control valve

M

B ZX215-1002116

Shop Manual - June 2013

4-111

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

3. During fine control (When control lever is returned) ● When disc (5) starts to return, plunger (1) is pushed up by the force of centering spring (3) and the pressure at port (P1). f

T

A

1

● If the pressure of port (P1) is lowered excessively, plunger (1) is pushed down by metering spring (2).

RI C

● Because of this, orifice (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released.

D

P

● Orifice (f) is shut off from drain chamber (D), and it is almost simultaneously interconnected to pump pressure chamber (PP). Pump pressure is supplied until the pressure at port (P1) recovers to the level equivalent to the lever position.

Pilot pump

AM E

P1

f1

P2

PP

M

A

Control valve

M

B ZX215-1002117

4. At full stroke

LA

TI N

● When the spool of the control valve returns, the oil in drain chamber (D) flows in from orifice (f) in the valve on the side that is not working. The oil passes through port (P2) and enters chamber (B) to replenish the chamber with pressurized oil.

NY

● Disc (5) pushes down piston (4), and retainer (9) pushes down plunger (1).

D f

T

1

SA

● Orifice (f) is shut off from drain chamber (D), and is interconnected to pump pressure chamber (PP). ● Therefore, the pilot pressure oil from the self pressure reducing valve passes through orifice (f) and flows to chamber (A) from port (P1) to push the control valve spool. ● The oil returning from chamber (B) passes from port (P2) through orifice (f) and flows to drain chamber (D).

4-112

P

f1 Pilot pump

A

Shop Manual - June 2013

P1

M

P2 PP

Control valve

M

B ZX215-1002118

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.6.8.2 Travel PPC valve

A

A

RI C

T

AM E

T

P

P

A

P5

P1

2

LA

P2

P6

TI N

P5

3

SA

NY

4

1

P4

P:

From pilot pump

P3 ZX215-1002119

P4: R.H. forward

P1: L.H. reverse

P5: Travel signal

P2: L.H. forward

P6: Travel signal

P3: R.H. reverse

T:

To tank

Shop Manual - June 2013

4-113

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

37~30Nm

B

65~45Nm 1

A

8~6Nm

RI C

2

3

AM E

4 5 6 C

C 2,4

TI N

7

1,3 B

NY

LA

13~11Nm

B-B

SA

C-C

8~6Nm ZX215-1002120

1)

Plate

5)

Centering spring

2)

Body

6)

Metering spring

3)

Piston

7)

Valve

4)

Collar

4-114

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Operation 1. When in neutral ● Ports (A) and (B) of the control valve and ports (P1) and (P2) of the Pilot valve are connected to drain chamber (D) via orifice (f) in plunger (1).

D f T

2. Fine control (Neutral to fine control)

● Pilot pressurized oil of the control pump is led to port (A) from port (P1) via orifice (f).

LA

● As a result, plunger (1) moves up and down until the force of metering spring (2) is balanced with the pressure at port (P1).

A A

P2

B

Control valve

ZX215-1002121

5 4 9

D

2 f

T P 1

PP

Pilot pump

SA

NY

● The relationship of the position of plunger (1) and body (10) [orifice (f) is in the middle between drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) contacts plunger (1).

RI C P1

TI N

● When the pressure at port (P1) becomes higher, plunger (1) is pushed back and orifice (f) is shut off from pump pressure chamber (PP). At almost the same time, it is connected to drain chamber (D) to release the pressure at port (P1).

1 Pilot pump

AM E

● When piston (4) is pushed by lever (5), retainer (9) is pushed, plunger (1) is also pushed by metering spring (2), and moves down. When orifice (f) is shut off from drain chamber (D), it is almost simultaneously interconnected to pump pressure chamber (PP).

P

● Metering spring (2) contracts in proportion to the stroke of the control lever.

P1

P2 10

A

Control valve

B ZX215-1002122

● Pressure at port (P1) also rises in proportion to the stroke of the control lever. ● In this way, the control valve spool moves to a position where the pressure of chamber (A) (same as pressure at port (P1)) and the force of the return spring of the control valve spool are balanced. Shop Manual - June 2013

4-115

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

3. Fine control (When control lever is returned) ● When lever (5) starts to return, plunger (1) is pushed up by the force of centering spring (3) and pressure at port (P1).

5

● Because of this, orifice (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released.

3

D

A

2 f

● If the pressure of port (P1) is lowered excessively, plunger (1) is pushed down by metering spring (2).

T

RI C

P 1 Pilot pump

A

TI N

● Pump pressure is supplied until the pressure at port (P1) recovers to the level equivalent to the lever position.

P1

4. At full stroke

LA

● When the spool of the control valve returns, the oil in drain chamber (D) flows in from orifice (f) in the valve on the side that is not working. The oil passes through port (P2) and enters chamber (B) to replenish the chamber with pressurized oil.

Control valve

B ZX215-1002123

5 4 D

9 f T

NY

● Lever (5) pushes down piston (4), and retainer (9) pushes down plunger (1).

SA

● Orifice (f) is shut off from drain chamber (D), and is interconnected to pump pressure chamber (PP).

P

f’

1 PP

Pilot pump

● Therefore, the pilot pressure oil from the self pressure reducing valve passes through orifice (f) and flows to chamber (A) from port (P1) to push the control valve spool. ● The oil returning from chamber (B) passes from port (P2) through orifice (f) and flows to drain chamber (D). 4-116

PP

P2

AM E

● Orifice (f) is shut off from drain chamber (D), and it is almost simultaneously interconnected to pump pressure chamber (PP).

f’

Shop Manual - June 2013

P1 A

P2

Control valve

B ZX215-1002124

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.6.9 Solenoid valve Pilot valve lock, travel speed, bucket confluence, swing priority

2

3

4

5

T A6

A3

A2

A1

P1

TI N

AM E

A4

RI C

A

1

WX13060401

Travel hi/lo speed solenoid valve

T:

To oil tank

2)

Swing priority solenoid valve

P:

From accumulator and pilot pump

3)

Bucket confluence solenoid valve

A1

To center swivel joint port

4)

Boom to arm priority solenoid valve

A2

To main valve port PsP

5)

Pilot lockout solenoid valve

A3

To main valve port Xbp2

A4

To main valve port PnA2

A6

To pilot valve block P

SA

NY

LA

1)

NOTE: For the location of the solenoid valve on the machine, see “Hydraulic equipment layout” on page 4-24.

Shop Manual - June 2013

4-117

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.6.10 Accumulator

1

A

2

RI C

3

AM E

4

5

2)

Shell

3)

Poppet

4)

Holder

5)

Bladder

6)

Oil port

Specifications Gas capacity: 300 cm³

LA

Gas plug

ZX215-1002126

SA

NY

1)

TI N

6

4-118

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.6.11 Pilot oil filter K 1 K 2

A

型号 压力 精度

RI C

3

5

AM E

4

LA

TI N

6

3

NY

ZX215-1002127

Specifications

Name plate

Max. delivery: 40 L/min

2)

Head cover

Filter fineness: 10 μm

O-ring

Operating pressure: 20 Mpa

Seal

Max. operating pressure: 40 Mpa

5)

Filter

Pressure loss: 0.05 Mpa

6)

Case

Max. allowable pressure difference: 1 Mpa

3) 4)

SA

1)

Specification of inlet/outlet port o-ring: 30×3.1

Shop Manual - June 2013

4-119

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.6.12 Pump oil pressure sensor

1

3

2

A

B

RI C

A

C

4

1)

Pressure connector

2)

Name plate

3)

Connector

4)

Vent hole

AM E

ZX215-1002128

TI N

Function

SA

NY

LA

● This sensor measures pump oil pressure and uses it to control various machine operations. When oil pressure compresses the diaphragm, it deforms and this is detected in the form of electric signals.

4-120

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.6.13 Hydraulic cylinder Boom cylinder

5340±50N·m 544.9±5.1kgm

1

3

RI C

A

2

56.9±10.7N·m 5.8±1.1kgm

AM E

267±35N·m 27.2±3.6kgm

Arm cylinder

1

LA

367±35N·m 37.4±3.6kgm

TI N

2

ZX215-1002129

7900±50N·m 806.1±5.1kgm

3

56.9±10.7N·m 5.8±1.1kgm ZX215-1002130

5480±50N·m 559.2±5.1kgm

1

3

SA

2

NY

Bucket cylinder

56.9±10.7N·m 5.8±1.1kgm

267±35N·m 27.2±3.6kgm

ZX215-1002131

Shop Manual - June 2013

4-121

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

100 hours greasing Unit: mm

3

Standard size

Boom

85

Arm

95

Bucket

80

Boom

80

Arm

80

Bucket

70

Boom

70

Arm

80

Clearance between piston rod and bushing

Clearance between piston rod support pin and bushing

Clearance between cylinder bottom support pin and bushing

Bucket

70

Check item

LA

500 hours greasing No.

NY

Cylinder Clearance between piston rod and bushing

SA

1

2

3

Clearance between piston rod support pin and bushing

Clearance between cylinder bottom support pin and bushing

4-122

Tolerance Shaft -0.036 -0.090 -0.036 -0.090 -0.030 -0.076 -0.030 -0.076 -0.030 -0.076 -0.030 -0.076 -0.030 -0.076 -0.030 -0.076 -0.030 -0.076

Hole +0.222 +0.047 +0.222 +0.047 +0.258 +0.048 +0.246 +0.200 +0.246 +0.200 +0.246 +0.200 +0.246 +0.200 +0.246 +0.200 +0.246 +0.200

Standard size

Boom

85

Arm

95

Bucket

80

Boom

80

Arm

80

Bucket

70

Boom

70

Arm

80

Bucket

70

Standard clearance

Clearance limit

0.083 – 0.312

0.412

0.083 – 0.312

0.412

0.078 – 0.334

0.434

0.230 – 0.322

1.0

0.230 – 0.322

1.0

0.230 – 0.322

1.0

0.230 – 0.322

1.0

0.230 – 0.322

1.0

0.230 – 0.322

1.0

Replace pin or bushing

Unit: mm Criteria

Tolerance Shaft -0.036 -0.090 -0.036 -0.090 -0.030 -0.076 -0.030 -0.076 -0.030 -0.076 -0.030 -0.076 -0.030 -0.076 -0.030 -0.076 -0.030 -0.076

Replace bushing

A

Cylinder

Remedy

RI C

2

Criteria

AM E

1

Check item

TI N

No.

Hole +0.222 +0.047 +0.222 +0.047 +0.258 +0.048 +0.246 +0.200 +0.246 +0.200 +0.246 +0.200 +0.246 +0.200 +0.246 +0.200 +0.246 +0.200

Shop Manual - June 2013

Remedy

Standard clearance

Clearance limit

0.083 – 0.312

0.412

0.083 – 0.312

0.412

0.078 – 0.334

0.434

0.230 – 0.322

1.0

0.230 – 0.322

1.0

0.230 – 0.322

1.0

0.230 – 0.322

1.0

0.230 – 0.322

1.0

0.230 – 0.322

1.0

Replace bushing

Replace pin or bushing

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.6.14 Work equipment F

D

A

C

E

RI C

G

,

A

B

H

TI N

K

AM E

J

LA

ZX215-1002133

6

SA

NY

1

2

3

A-A

C-C

5

B-B G-G

H-H

E-E

,-,

D-D

F-F

Shop Manual - June 2013

4

J-J

K-K

ZX215-1002134

4-123

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

100 hour greasing Unit: mm Check item

Criteria

Clearance between pin connect1 ing boom and revolving frame and bushing

Standard size

Remedy

Tolerance

Standard clear- Clearance ance limit Hole

Shaft

90

–0.036 +0.140 0.141 ~ 0.211 –0.071 +0.105

1.0

A

No.

Clearance between pin connecting boom and arm and bushing

90

–0.036 +0.174 0.140 ~ 0.345 –0.071 +0.104

1.0

3

Clearance between pin connecting arm and rocker and bushing

70

–0.030 +0.335 0.305 ~ 0.395 –0.060 +0.275

1.0

4

Clearance between pin connecting arm and bucket and bushing

80

–0.030 +0.324 0.300 ~ 0.384 –0.060 +0.270

1.0

5

Clearance between pin connecting linkage and bucket and bushing

80

–0.030 +0.373 0.303 ~ 0.433 –0.060 +0.273

1.0

6

Clearance between pin connecting linkages and bushing

70

–0.030 +0.335 0.305 ~ 0.395 –0.060 +0.275

1.0

Check item

AM E

TI N LA

500 hour greasing

No.

RI C

2

NY

Clearance between pin connect1 ing boom and revolving frame and bushing

Standard size

Unit: mm Criteria

Remedy

Tolerance Shaft

Standard clear- Clearance ance limit Hole

90

–0.036 +0.131 0.110 ~ 0.202 –0.071 +0.074

1.0

Clearance between pin connecting boom and arm and bushing

90

–0.036 +0.166 0.110 ~ 0.237 –0.071 +0.074

1.0

3

Clearance between pin connecting arm and rocker and bushing

70

–0.030 +0.158 0.108 ~ 0.218 –0.060 +0.078

1.0

4

Clearance between pin connecting arm and bucket and bushing

80

–0.030 +0.137 0.104 ~ 0.197 –0.060 +0.074

1.0

5

Clearance between pin connecting linkage and bucket and bushing

80

–0.030 +0.166 0.116 ~ 0.226 –0.060 +0.086

1.0

6

Clearance between pin connecting linkages and bushing

70

–0.030 +0.154 0.104 ~ 0.214 –0.060 +0.074

1.0

SA

2

4-124

Replace

Shop Manual - June 2013

Replace

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Arm dimension

9 11 B

C

A

RI C

12 A

A

19

5

D 6

D

14

10

C 8

LA

A-A

TI N

13

15

7

B-B

16

NY

18

AM E

B

SA

17

4

C-C

D-D

1 3

2

WX13060402

Shop Manual - June 2013

4-125

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Unit: mm SY195/205/215C-9

No.

19

4-126

Tolerance

Standard size

Tolerance

1

φ80

+0.1 0

φ80

+0.1 0

2

107

±0.5 0

107

±0.5 0

3

310

-0.3 -0.8

310

-0.3 -0.8

4

φ90

-0.036 -0.071

φ90

-0.036 -0.071

5

549

±1

549

±1

6

158

±0.8

158

±0.8

7

835

±1

835

±1

8

2,911

±2

2,911

±2

9

2,643

±2

2,643

±2

10

411

±0.8

411

±0.8

11

640

0 -0.5

640

0 -0.5

12

600



600



13

458



458



14

1,483



1,495



15

φ80



φ80



16

326.5



326.5



17

φ80

+0.2 0

φ80

+0.2 0

Arm itself

311



311



When press fitting bushing

325



325



Min.

1,680



1,680



Max.

2,800



2,800



RI C

AM E

TI N

LA

NY

A

Standard size

SA

18

SY225C-9

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Bucket dimension

5

2 A 17

18

A

6

4 16

AM E

1

RI C

3

19 7

TI N

A

8

15

8

SA

NY

15

LA

13

10

14

12 9

11

20

21

22

A-A

Shop Manual - June 2013

WX13060403

4-127

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Unit: mm No.

SY195/205/215C-9

SY225C-9

Tolerance

Standard size

Tolerance

1

457.5

±0.5

457.5

±0.5

2

22

±0.5

22

±0.5

3

91.8°



91.8°



4

458



458



5

1,483



1,483



6

177



177

7

45°

45°

8

φ80

9

348.5

10

37

— +0.2 0 +0.2 0 —

11

107



12

473.5



13

φ23.5



14

φ190

15

φ136

16

131

17

125

18

R180

19

R140

20

57

21

326.5

RI C



37

— +0.2 0 +0.2 0 —

107



473.5



φ23.5





φ190





φ136





131





125





R180





R140





57



±0.5

326.5

±0.5

φ80

NY

LA

TI N

AM E

348.5

SA 4-128

A

Standard size

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.7 Air Conditioning System

1

2 3

5

C C

TI N

C

AM E

RI C

A

4

A

NY 2)

6

7

8 ZX215-1002137

SA

1)

B

LA

C C

A. Fresh air

Hot water piping A/C compressor (DENSO.2)

B. Recirculated air

3)

Refrigeration piping

4)

Condenser (SG447750-A040)

5)

Receiver tank (DENSO.4)

6)

Hot water return piping

7)

A/C unit assembly (SG443180-9320)

8)

Air duct

C. Warm air/cool air

Shop Manual - June 2013

4-129

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.7.1 A/C components layout drawing

2 1 3

5

LA

TI N

AM E

RI C

A

4

NY

7

6 ZX215-1002138

Sunlight sensor

5)

Compressor

2)

Control panel

6)

Fresh air sensor

3)

Air conditioning unit

7)

Recirculated air sensor

4)

Condenser

4-130

SA

1)

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.7.2 Control panel

2

3

4

5

RI C

A

1

8

7

CZ205-1203020G

AM E

6

OFF switch

5)

Auto mode switch

2)

Fan speed control switch

6)

Air circulation control switch

3)

Temperature control switch

7)

LCD display

4)

Air outlet mode switch

8)

A/C switch

SA

NY

LA

TI N

1)

Shop Manual - June 2013

4-131

A RI C 3

AM E

FL1

7

8

8

1.25L D 1.256

FURM 20A 1.25R

RLBM 10 15

2RL 1.25RL MR 2G

M 10

10

200W

12

12

RLCH

10 BLCM 3

2

8

13

13

12

FUM 5A

+B 6

14

13

16

SW H OFF ACC ON START 15

16

18

13

19

19

19

13 20

15

3 22

21

22

SSD

16

B G1 G2 ACC M ST

Wiring diagram

12

RLCC RLCD RLBM

16

16

14

17

15

THAM THW THI THF

28 15

8

TI N

3

8

RLCC

10

11

4

BLC

1

G

15

23

27 4 15

20

28

ACM

21

27

M

29

2

M

MRF

25

1

MV1

31 22 32

31

25

26

24 22 26

23

24

25

22

25

24

30

30

M

32

GND

FUCD 15A

RLCD

9

9

ECC 40W 15

SPHL

0.5B

MAM

REC Vz Pt

60A

CMB

RLCH 03

2B

FFE

2

2

1 1

FLZ 40A

02

MCD SPCD M 80W

02

LA

2 5 5

SW 6

RCD RLCH 02

2B

1.25R 0.50

7 7

D1

D2

03

NY

5

1

BAT ACC

4 4

02

2B

0.85B

4

CMB CM 02

02

SA

G

01

1.25B

RLSF

3

06

06

1.25B

9

15

38

32

33

M

26

34

35

10

34 35 35 22

MV2

Shop Manual - June 2013

4-132

SY195/205/215/225C9 Crawler Hydraulic Excavator

Structure and Function

4.7.3 Circuit diagram

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Wire No. Diameter/Color code

Wire color

Wire No. Diameter/Color code

Wire color

Black

0.5VW

Violet+white

Br(R)

Brown

0.5YB

Yellow+black

0.85W

White

0.5WO

White+orange

RL

Red+blue

0.5PB

Pink+black

G

Green

0.5VR

Violet+red

0.5BL

Black+blue

0.5BG

Black+green

0.5R

Red+blue

0.5WY

White+yellow

0.5Y

Yellow

0.5WR

0.5BR

Black+red

0.5BrY

Brown+yellow

0.5BY

Black+yellow

0.5GW

Green+white

0.5LO

Blue+orange

0.5PG

Pink+green

0.5RY

Red+yellow

0.5BW

Black+white

0.5LgR

Light green+red

RI C 0.5GO

Green+orange

0.5Sb

Sky blue

0.5OW

Orange+white

1.25V

Violet

1.25RG

Red+green

1.25RW

Red+orange

0.85GL

Green+Blue

AM E

Brown+white

Name

Code

ACM

A/C amplifier

FUCD

Condenser fuse

RLCH

BAT

Battery

FUM

A/C main fuse

RLSF

BLC

Speed regulating resistor

G

Alternator

SSD

Battery relay

MAM

A/M servo motor

SPCD

Diode

MB

Blower motor

SPHL

Sunlight sensor Condenser pressure switch HI/LO pressure switch

D1

Diode 1

MCD

SW

Switcher

D2

Diode 2

MRF

THAM

External air thermistor

ECC

Compressor clutch

MV1

Condenser motor Internal/External air servo motor Air outlet servo motor

THF

Anti-frosting thermistor

FL1

Fuse

MV2

FRONT outlet servo motor

THI

Internal air thermistor

FL2

Fuse

RCD

Condenser resistor

THW

Water temp. thermistor

FUBM

Blower fuse

RLBM

Blower main relay

RLCC

Compressor relay

RLCD

Condenser relay

SA

D

NY

CMB

Code

White+red

0.5BrW

TI N

Name

LA

Code

A

B

Shop Manual - June 2013

Name Condenser high speed relay Protective relay

4-133

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.7.4 Refrigeration principle 4.7.4.1 Refrigeration cycle diagram

Expansion valve

Cool air

Lo temp\Lo press liquid (Mist)

A Condenser

Hi-temp hi-pres gas

Hi-pres. side

Lo-pres. side

TI N

Compressor

AM E

Out side fresh air

Receiver

Air in cab

RI C

Cooling fan

Blower

Hi temp\Hi press liquid

Lo temp\Lo press gas

Evaporator

Hot air

Hi-pressure portion

ZX215-1002141

LA

Lo-pressure portion

4.7.4.2 Heating cycle diagram

Water valve control

Water pump

Hot air

SA

NY

Radiator

Engine

Blower motor

Internal air

Low tempr water High temp water

4-134

ZX215-1002142

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.7.5 Compressor 3 1

4

2

RI C

A

16

15

AM E

14

LA

12

TI N

13

5

11

10

6

9

8

7

Stator

9)

2)

Front radial bearing

10) Front cylinder block

3)

Thrust bearing

11) Piston

4)

Front radial bearing

12) Front cylinder head

6) 7) 8)

SA

5)

NY

1)

ZX215-1002143

Slipper

Rear cylinder head

13) Shaft seal

Safety valve

14) Main shaft

Rear cylinder block

15) Hub

Swash plate

16) Rotor

Shop Manual - June 2013

4-135

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Operating principle Compressor type: 10S15C. This compressor has 5 plungers in total with a piston on both sides of each plunger. The rotation of the swash plate drives the pistons to move Process1

back and forth and transforms the refrigerant sucked from the evaporator from low temperature and low pressure gas state to high temperature and high pressure state. Process2 HI press.end pipe LO press.end pipe

A

HI press.end pipe LO press.end pipe

RI C

Valve plate

Main shaft and swash plate

AM E

Outlet valve disc

Intlet valve disc

Process6

HI press.end pipe LO press.end pipe

SA

NY

LA

HI press.end pipe LO press.end pipe

TI N

Process3

Process5

HI press.end pipe LO press.end pipe

Process4 HI press.end pipe LO press.end pipe

ZX215-1002144

4-136

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.7.6 Clutch

Stator coil

3)

Snap ring

4)

Ball bearing

5)

Stator

6)

Center piece

1 2 3 4

A

2)

● The electromagnetic clutch is used to transmit moment of torsion. When the engine is operating, the compressor may not be working. The clutch controls the operation of the compressor only when the air conditioner is under refrigerating mode. ● Operating principle

RI C

Rotor

5

6

ZX215-1002145

AM E

1)

SA

NY

LA

TI N

When the A/C switch is turned on, the clutch coil with an electromagnet generates a magnetic field and attracts the metal piece. The stator and rotor of the clutch are engaged and drives the main shaft of the compressor into rotation.

Shop Manual - June 2013

4-137

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.7.8 Condenser

1 4

2

AM E

RI C

A

3

Condenser core

2)

Bracket

3)

Bolt with gasket

4)

Refrigerant inlet

5)

Refrigerant outlet

ZX215-1002146

TI N

1)

5

LA

Function

NY

● The condenser converts high-temperature, high-pressure gas refrigerant (16Kg/cm², about 80°C) to high-temperature and highpressure liquid refrigerant (16Kg/cm², below 60°C) through radiating.

4.7.7 Expansion valve

SA

Evaporator

1)

Spring

2)

Diaphragm

3)

Probe

4)

Needle valve

2 1

Operating principle

3

● Refrigerant from the receiver tank spurts out via the orifice, turns into low-temperature, low-pressure liquid (mist) after expanding, and enters the evaporator. 4-138

Shop Manual - June 2013

4 Reservoir

Compressor ZX215-1002147

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.7.9 Evaporator 1)

Expansion valve

2)

Evaporator

Inlet Outlet

3)

Receiver/dehydrator

4)

Desiccant

Function

RI C

NY

2)

ZX215-1002148

2 1

LA

1)

TI N

4.7.10 Receiver tank

2

1

AM E

● The evaporator is a kind of heat exchanger that looks like a condenser. Hot air in the cab is conducted into the evaporator via the blower motor and undergoes heat exchange with the surface of the evaporator. Heat is absorbed and hot air turns into cold air, which flows into the cab through the air ducts. Evaporator surface absorbs heat→Refrigerant in the evaporator absorbs heat → Refrigerant evaporates . Evaporated refrigerant (gas) is absorbed by the compressor.

A

Operating principle

3

● Temporary storage of refrigerant

SA

● Dehydration of refrigerant 4

● Dust removal from refrigerant ● Measure the volume of refrigerant

ZX215-1002149

Shop Manual - June 2013

4-139

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.7.11 Pressure switch 1)

O-ring

2)

Mobile contact point

3)

Hood

4)

Plug and fixed contact

5)

Spring

6)

Chamber

7)

Diaphragm

Pressure

1 7

2

Function

3

5

AM E

● The pressure switch is installed between the receiver tank and the expansion valve (hi-pressure pipe). It is a combination switch (Hi-Lo pressure combination switch).

RI C

A

6

ZX215-1002150

TI N

● When pressure is excessively high, the compressor stops.

4

LA

● When pressure and temperature is very low, the compressor stops.

Feature

NY

Operating features

SA

DIFF HI pressure operating value Above 0.02 MPa LO pressure operating value

DIFF

ON

0.59±0.2 MPa

OFF 0.196±0.02 MPa

2.94~3.19 MPa

0.196~0.250 MPa

ON MID pressure operating value

4-140

OFF

1.23±0.1 MPa

1.52±0.08 MPa

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.7.12 Fresh air sensor

Service voltage range

4.4~5.6 V

Service temp range

-30~60 °C

Storage temp range

-40~90 °C

Resistance value

1700±85Ω

B constant

3900±195 K

Allowable operating current

1.6 mA (MAX)

8

A

Specification

10

6 4 2

-10

0

AM E

Item

Resistance value

Technical specifications

12

RI C

/K¡

The fresh air sensor is installed beside the condenser or around the fresh air inlet. It measures the temperature of outside air and it is composed of thermistors.

10

20

30

40

AT

ZX215-1002151

WARNING

TI N

4.7.13 Refrigerant

LA

● Obey local material disposal regulations. Never discharge refrigerant directly into the air.

NY

● Refrigerant R134 a is a harmless gas under room temperature. It will change into highly toxic gas when burning.

SA

● Refrigerant getting into eyes may cause blindness. It may cause frostbite if splashed on your skin. 1. General property ● High heat absorption and easy liquefaction ● Non-flammable, nonexplosive ● Stable chemical composition ● Non-toxic ● Non-corrosive ● No hazard to clothing

Shop Manual - June 2013

4-141

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

2. Refrigerant cycle ● After evaporation in the evaporator, refrigerant turns from gas into liquid via the compressor and the condenser, which finishes a refrigerant cycle.

Compress HI press. side(outlet): HI temp\HI press.\Gas Pressure/Temperature:16Kg/cm²ˈapprox. 80ć

A

Absorb heatėEmit cold air

RI C

Compressor IntakeėDischarge

Compressor LO press. side (inlet): LO temp?LO press.?Gas Pressure/Temperature:2Kg/cm²,approx. 8ć Evaporator

Condensor (outlet)˖HI temp?HI pressure?Liquid Pressure/Tempterature˖16Kg/cm²ˈBelow 60ć

Expansion valve Hi pressureėLo pressure Hi tempėLo temp LiquidėMist

TI N

Condensor Via radiating:Gas refrigerantėLiquid refrigerant

AM E

Condensor (outlet): LO temp\LO press.\Mist Pressure/Temperature: 2Kg/cm²ˈapprox. 0~2ć

● Refrigerant cycle principle (pressure - enthalpy diagram)

LA

lgp

Liquefaction completed

NY

Condensing process

Liquid

Expansion throttle

SA

Liquefaction starts Condensor

Throttling point

Expansion valve

Refrigerant cyclic curve

Compressing process

Compressor

Evaporating process Evaporator

Gasification completed

Gas-liquid mixture

h=u+Apv(kJ/kg) UInternal energy pPressure

4-142

VSpecial volume AJoule equivalent

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

3. Feeding of refrigerant ● Filling method and volume: 1) Refrigerant: HFC-134a 2) Feeding volume: 850±50 g (for reference)

AM E

RI C

A

3) Feeding method: Feeding of liquid refrigerant from the low-pressure end is not allowed. If feeding operation fails, discharge the refrigerant that has been fed before refeeding.

TI N

● Inspect the state of the refrigerant in the A/C circulation system through the sight glass:

LA

1) Correct feeding: Foam is hardly observed when the refrigerant is flowing. When engine speed increases from idling to 1500 rpm, foam disappears and the refrigerant turns clear.

ZX215-1002153

Sight glass

Proper filling

NY

2) Over-feeding: No foam can be observed when refrigerant is flowing.

SA

3) Under-feeding: Foam is always observed when refrigerant is flowing.

Shop Manual - June 2013

Inadequate filling ZX215-1002154

4-143

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4. Evacuation

RI C

A

● No moisture shall exit in the air conditioning unit. Refrigerant (R134a) is soluble in water. Very small amount of moisture in the unit can cause the orifice of the expansion valve to ice up, or cause the compressor valve to rust. To avoid such problems, moisture in the system shall be removed before refrigerant is added. To minimize the residual moisture in the system, moisture in the system can evaporate through evacuating.

Step 1: Connect the manifold pressure gauge 1) Close the high-pressure valve (HI) and low-pressure valve (LO) of the manifold pressure gauge.

AM E

Evacuating steps

Valve

Lo-pres.gauge

LO HI LO HI above 750mmHg OFF OFF ON ON

Lo-pres. gauge

Hi-pres. gauge

TI N

2) Connect the hoses (red, blue) to the auxiliary valve of the compressor. Red hose – High pressure side (Mark D)

Hi-pres. valve(ON)

Lo-pres. valve (ON) Green

LA

Blue

S

Vacuum pump (running)

NY

NOTE: Connect the end of the hose with a L to the auxiliary valve of the compressor. If connected inversely, the valve will not open. Besides, do not inversely connect the high-pressure end and the lowpressure end.

SA

3) Connect the green hose to the vacuum pump.

4-144

D

Red

Blue hose – Low pressure side (Mark S)

Shop Manual - June 2013

Compressor ZX215-1002155

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Step 2: Evacuation 1) Open the high-pressure valve (HI) and lowpressure valve (LO) on the manifold pressure gauge. 2) Turn on the vacuum pump and evacuate for about 15 minutes.

RI C Valve

TI N

1) Keep the Hi- and Lo-pressure valve of the manifold pressure gauge under closed state for more than 5 minutes, and make sure the pointer on the gauge does not return to zero.

AM E

Step 3: Air - proof check

A

3) When negative pressure reading on the gauge (degree of vacuum) reaches above 750 mmHg, turn off the vacuum pump and close the Hi-pressure valve and the Lopressure valve on the gauge.

LA

2) If the pointer returns to near zero, a leakage is available somewhere. Check and adjust the pipe joint. Tighten the joint and conduct another evacuating operation until no leakage is detected.

Lo Hi OFF OFF

Wait 5 min. or more Lo-press. gauge returns to 0

Lo-press. gauge

Pointer returns to 0

Tighten pipe joint

SA

NY

ZX215-1002156

Shop Manual - June 2013

4-145

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Step 4: Leak check 1) Connect the green hose that is previously connected to the vacuum pump to the fluorine cylinder.

Vent valve Release air

A

Open

Blue

Green

Fluorine cylinder

AM E Lo

Hi Lo-press gauge 2

OFF ON

Lo-pres.valve (OFF)

Lo

Hi

OFF OFF

Open Hi-pres.valve

Cylinder valve (ON)

D S R134a

Compressor

Fluorine cylinder ZX215-1002158

SA

NY

at 1kgf/cm

Lo-pres. gauge reads1kgf/cm2

5) Make necessary repairs (tightening) if leakage is observed.

4-146

ZX215-1002157

Valve

TI N

LA

4) Use a leak detector to check if leakage is available in the cooling system.

R134a

Red

To compressor

3) Add refrigerant until pressure reading on the Lo-pressure gauge is 1kgf/cm² . Hipressure valve of the gauge is open at this time. Close the Hi-pressure valve when feeding is finished.

Hi

OFF OFF

RI C

2) Connect the other end of the green hose to the pressure gauge. Open the valve of the cylinder and press the vent valve of the pressure gauge. (Do not press the valve with naked hand to avoid frostbite caused by refrigerant). Release the air in the hose with the pressure of the refrigerant. (Release the vent valve when you hear a squeezing sound).

Valve Lo

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

5. Refrigerant charging operation ● When evacuation is finished, add refrigerant into the cooling system as per the following instruction:

Performance testing

A

RI C

Pres. gauge

Tighten pipe joint

Air leak check

Add refrigerant

normal

Air leak check

Pres. gauge

Add refrigerant kgf/cm2

Wait 5 min.

Air-proofness check

More than 15 min.

Evacuation ends

Evacuation starts

75cm-Hg or more

(1) Compressor stopped, charge at hi-press end

abnormal

Check leak point

Charge at the hi-pressure side

AM E

(2)Compressor running, add at lo-press end

Valve

1. Remove the green hose of the manifold pressure gauge from the vacuum pump and connect it to the fluorine cylinder.

TI N

2. Loosen the cylinder valve and press the vent valve on the gauge. Use the pressure of the refrigerant to release the air in the hose.

Lo

Vent valve

Open

Loosen this nut Blue

NOTE: Release the vent valve when you hear a hissing sound.

LA

Hi

OFF OFF

Red

Green

R134a

Fluorine cylinder

To compressor

ZX215-1002159

NY

CAUTION

SA

● Do not press the valve with naked hand to avoid frostbite. 3. Open the hi-pressure valve of the manifold pressure gauge and the cylinder valve with the engine stopped. Fill about 600g of refrigerant. 4. Close the hi-pressure valve of the pressure gauge and shut the cylinder valve.

Valve Lo

Hi

OFF ON

Lo-press. valve (OFF)

A cylinder (about 600g)

Lo

Hi

OFF OFF

gDo not operate compressor gDo not open Lo-pressure valve

Open Hi-press. valve

Fluorine cylinder valve (ON)

D S

R134a

ZX215-1002160

Shop Manual - June 2013

4-147

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

CAUTION ● Do not operate the compressor when refrigerant charging is in progress. Otherwise, refrigerant will counterflow and cause the cylinder and hoses to explode.

RI C

A

● Operating the compressor with no refrigerant in the system will cause damage to the compressor.

Charge at the lo-pressure side (refill) 1. Check that the hi-pressure valve of the manifold pressure gauge is closed.

AM E

● Do not open the lo-pressure valve of the manifold pressure gauge; otherwise, the compressor will be damaged.

2. Start the engine.

TI N

Hi-press. valve (OFF)

3. Turn on the A/C unit. Adjust Temperature control switch to minimum.

H I

LA

4. Adjust engine speed to 1300 – 1500 rpm.

Start the engine

5. Open the Lo-pressure valve of the manifold pressure gauge and the cylinder valve. Add refrigerant until no foam is observed through the sight glass.

1300~1500rpm

NY

ZX215-1002161

Valve

SA

Remark:

Manifold pressure gauge reading (for reference): HIGH pressure: 13~17kgf/cm² (when ambient temperature is 30°C)

ON

Manifold pressure gauge

Lo Hi ON OFF

When no foam is observed

Lo-press. gauge (1.5~2.5kgf/cm2) Lo-press. valve (ON)

Lo Hi OFF OFF

Hi-press. gauge (13~17kgf/cm2) Hi-press. valve (OFF) (Never open it)

Fluorine cylinder valve (ON)

LOW pressure: 1.5~2kgf/cm² (when ambient temperature is 30°C).

Fluorine cylinder (never placed upside down)

Compressor running ZX215-1002162

4-148

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

6. When refrigerant charging is finished, close the Lo-pressure valve of the manifold pressure gauge and the valve of the fluorine cylinder. 7. Check carefully for air leaks with a leak detector.

CAUTION

RI C AM E

TI N

● When engine is running and charging in progress, placing the fluorine cylinder upside down will cause liquid refrigerant to be sucked directly into the compressor and cause liquid compression, resulting in equipment damage.

A

● Opening the Hi-pressure valve of the pressure gauge will cause pressurized gas to counterflow and cause the hoses and the fluorine cylinder to explode, resulting in serious damage.

8. When ambient temperature is low

Valve Lo Hi

LA

When refrigerant charging gets difficult due to low temperature, put the cylinder in warm water (max. 40°C). 9. When ambient temperature is high

SA

NY

When ambient temperature is very high, cool the compressor with an electrical fan.

ON OFF

Lo-pressure valve (ON)

When no foam is seen

Lo

Hi

OFF OFF

Hi-pressure valve (OFF)

Cylinder valve (ON)

Water less than 40°C (Do not use hot water)

Compressor running ZX215-1002163

Shop Manual - June 2013

4-149

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Replace the fluorine cylinder When the refrigerant in a cylinder is used up, replace the cylinder as per the following instruction: 1. Close the Hi- and Lo-pressure valves of the manifold pressure gauge.

Handle

Air hose connector

2. Raise the needle and disc plate of the cylinder and remove the empty cylinder.

A RI C

3. Install a new cylinder onto the cylinder valve.

Needle valve

Disc plate

1) Tighten the valve of the fluorine cylinder, and then, loosen it a bit. 2) Open the Lo-pressure valve of the manifold pressure gauge a bit.

AM E

4. Release the air in the hose as per the following instruction:

Gasket

Refrigerant cylinder

ZX215-1002164

LA

TI N

3) Press the vent valve and allow a little refrigerant to come out. Immediately close the valve of the cylinder and the Lopressure valve of the manifold pressure gauge.

Valve Lo Hi

CAUTION

Loose OFF

● Do not press the valve with naked hand to avoid frostbite.

NY

Close the Lo-pressure valve once you hear the hissing sound

SA

5. Turn the handle of the cylinder valve to pierce the cylinder and continue charging operation.

Loosen the valve a bit

Lo-pressure valve Green

Blue Red

To compressor

R-134a

Refrigerant cylinder ZX215-1002165

4-150

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

6. Fault testing with manifold pressure gauge After the engine has been preheated, read the pressure value on the gauge under the following conditions: 1) Temperature at air inlet: 30 – 35°C 2) Engine speed: 1500 rpm

A

3) Fan speed: High

RI C

4) Temperature control: Minimum. 5) Air circulation mode: Recirculation

Gauge reading: Lo-pressure end: 0.15~0.25 Mpa (1.5~2.5 Kgf/cm²)

TI N

Hi-pressure end: 1.37~1.57 Mpa (14~16 Kgf/cm²)

AM E

● Cooling system under normal condition

04

3

02 2 1

4

5

06

6

07

{cmHg kgf/cm2} 8 0 8.5 -50

0

-76

-01

15

05

20

10

5

25

{cmHg kgf/cm2}

08 0

085

25

30 3

0

MPa

-76 35 -01

35 MPa

R134a

SA

NY

2

15

1

7

LA

01

15

05

03

ZX215-1002167

Shop Manual - June 2013

4-151

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

● Moisture in the refrigerating system Symptom: Intermittent refrigeration to non-refrigeration

04

07

{cmHg kgf/cm2} 8 0 8.5 -50 0

1 10

7

1

05

25

5

{cmHg kgf/cm2}

15

085

0

MPa

25

30 3

0 08

-76 -01

20

A

06

6

2

2

15

5

-76 35 -01

35

MPa

RI C

3

4

02

01

15

05

03

Symptom

Cause

AM E

ZX215-1002168

Analysis

Remedy

SA

NY

LA

TI N

● When the system is ● Moisture in the system ● Over-saturation of de- ● Replace receiver/ operating, pressure ices up at the expanhydrator. dehydrator at the Lo-pressure sion valve causing ● Moisture in the system ● Remove the moisend unstable (somecircular temporary ices up at the expanture in the system times vacuum, stop. When ice melts, sion valve and hinders through constant sometimes normal) the system becomes the circulation of the pumping. normal again. refrigerating system. ● Add proper volume of new refrigerant.

4-152

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

● Insufficient refrigeration Symptom: Insufficient refrigeration

04

5

-76 -01

15

05

5

25

{cmHg kgf/cm2}

0

085

-76

Cause

● Air leaks somewhere in the refrigerating sys● Foam is continuously obtem served via the sight glass

ZX215-1002169

Remedy

● Insufficient ● Check for air leakage with a leak refrigerant in the detector. Make necessary resystem pairs. ● Leak of refrigerant

● Add proper amount of refrigerant. ● When connected with the gauge, if the reading is near zero, set the system under vacuum state after inspection and repair.

SA

NY

LA

● Insufficient refrigeration.

Analysis

TI N

● Pressure at both Hi- and Ho-pressure ends very low

35 MPa

AM E

Symptom

35

-01

MPa

30 3

0 08

25

A

07

{cmHg kgf/cm2} 8 0 8.5 -50 0

10

7

1

20

1

06

6

2

2

15

RI C

3

4

02

01

15

05

03

Shop Manual - June 2013

4-153

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

● Defective refrigerant circulation Symptom: insufficient refrigeration

04

07

{cmHg kgf/cm2} 8 0 8.5 -50 0

1 10

7

1

05

25

5

{cmHg kgf/cm2}

15

085

0

MPa

-76

25

30

0 08

-76 -01

20

A

06

6

2

2

15

5

3

35

-01 35 MPa

RI C

3

4

02

01

15

05

03

Symptom ● Pressure at both Hi- and Lo-pressure sides very low

Cause ● Contaminant in the reservoir hinders the flow of refrigerant.

Analysis

● Blocked reservoir

SA

NY

LA

TI N

● Frosting on the piping between parts and reservoir

AM E

ZX215-1002170

4-154

Shop Manual - June 2013

Remedy ● Replace reservoir

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

● Refrigerant not circulating Symptom: Non-refrigeration (intermittent refrigeration)

5 06

6

2

07

{cmHg kgf/cm2} 8 0 8.5 -50 0

10

-01

05

5

15

25

{cmHg kgf/cm2}

0

085

3

Cause

● Vacuum at Lo-pressure side; pressure at Hi-pressure side extremely low

● Moisture or contaminant in the refrigerant hinders the flow of refrigerant.

● Frosting or condensation on the pipes around the expansion valve or receiver/dehydrator

● Air leak at the thermal pipe of the expansion valve hinders the flow of refrigerant.

35

-01

35 MPa

Analysis

● Refrigerant not circulating

ZX215-1002171

Remedy

● Check the expansion valve and ERP. ● Blow the contaminant in the expansion valve or replace the expansion valve if necessary. ● Replace the receiver ● Release internal air and add refrigerant. If air leaks from thermal pipe, replace expansion valve.

SA

NY

LA

TI N

Symptom

-76

AM E

MPa

25

30

0 08

-76

20

1

7

1

2

15

RI C

3 02

01

15

05 4

A

04 03

Shop Manual - June 2013

4-155

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

● Over-charging of refrigerant or insufficient refrigeration of condenser Symptom: Insufficient refrigeration

04

07

{cmHg kgf/cm2} 8 0 8.5 -50 0

1 10

7

1

-01

05

25

5

{cmHg kgf/cm2}

15

085

0

MPa

25

30 3

0 08

-76

20

A

06

6

2

2

15

5

-76

35

-01 MPa

35

RI C

3

4

02

01

15

05

03

Symptom

Cause

Analysis

Remedy

● Over-filling of refriger- ● Over-filling of refriger- ● Clean the condenser ant in the system. Reant ● Check the working frigerating performance ● Condenser fins clogged condition of fan moinadequate. ● No foam can be obor fan motor error. tor served via the sight ● Insufficient refrigera● If the two above glass even when tion of condenser items are normal, engine speed drops. check the volume of refrigerant. Add refrigerant.

SA

NY

LA

TI N

● Pressure at both Hiand Lo-pressure sides very high

AM E

ZX215-1002172

4-156

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

● Air is observed in the refrigerating system Symptom: Poor refrigeration NOTE: If refrigerant is added with no evacuation operation performed, the following gauge reading will appear:

5 06

6

2

07

{cmHg kgf/cm2} 8 0 8.5 -50 0

10

-01

05

15

30

25

3

-76 35 -01

35

AM E

MPa

ZX215-1002173

Analysis

Remedy

● Air enters the refrigerant system

● Check if compressor oil is contaminated or inadequate.

TI N

● Pressure at both Hi- and ● Air enters the reLo-pressure ends very frigerating system high

LA

● Insufficient evacuation

● Evacuate and add new refrigerant.

SA

NY

● Foam is observed through the sight glass

{cmHg kgf/cm2}

0

085

Cause

● Lo-pressure piping feeling hot

25

0

MPa

Symptom

5

08

-76

20

1

7

1

2

15

RI C

3 02

01

15

05 4

A

04 03

Shop Manual - June 2013

4-157

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

● Improper installation of expansion valve/thermal pipe defect (wide opening) Symptom: insufficient refrigeration

04

1 10

7

1

0

06

6

07

{cmHg kgf/cm2} 8 0 8.5 -50 -01

05

5

25

{cmHg kgf/cm2}

15

3

085

-76

0

35

-01

MPa

25

30

0 08

-76

20

A

5

2

2

15

35

MPa

RI C

3

4

02

01

15

05

03

Symptom

● Expansion valve de● Over-filling of fect, or improper instalrefrigerant in lation of thermal pipe Lo-pressure piping

● Expansion valve opening very wide

SA

NY

LA

● Frosting or condensation on Lo-pressure piping

Analysis

TI N

● Pressure at both Hi- and Lo-pressure ends very high

Cause

AM E

ZX215-1002174

4-158

Shop Manual - June 2013

Remedy

● Check the installation of thermal piping ● If thermal piping is normal, check the expansion valve. Replace defective expansion valve if observed.

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

● Compressing error Symptom: No refrigeration

04

5

-76 -01

15

05

{cmHg kgf/cm2}

08 0

085

● Pressure at Lo-pressure side very high

● Compressor internal leakage

-76 35 - 01 MPa

35

AM E

Cause

30

Analysis

● Compressing fault; ● Leaking or damaged valve, loosened parts

ZX215-1002175

Remedy ● Repair or replace compressor

SA

NY

LA

TI N

Symptom

25

3

0

MPa

● Pressure at Hi-pressure side very low

5

25

A

07

{cmHg kgf/cm2} 8 0 8.5 -50 0

10

7

1

20

1

06

6

2

2

15

RI C

3

4

02

01

15

05

03

Shop Manual - June 2013

4-159

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.7.14 Compressor oil Oil shall be added into the A/C system for lubrication. Compressor oil is solved in the refrigerant and circulates in the system. When the air conditioning system is shut down, compressor oil will stay inside the components. If no compressor oil is added into the system when replacing components, inadequate lubrication will result. Add compressor oil according to the chart below: Replaced component See "CAUTION" below

40

Evaporator 40

ND8# (10P, 10PA, 10S series compressor)

Compressor oil grade

A

Condenser

RI C

Volume (ml)

Compressor

ND9#(TV series compressor)

AM E

CAUTION

● Add oil into a new compressor according to the required volume of the system. When the compressor is to be replaced, discharge the surplus oil in it. ● Over-filling of compressor oil will reduce the refrigerating capacity. Short of compressor oil in the system will cause compressor abnormality.

SA

NY

LA

TI N

● Protect pipe joints and O-rings from contamination when disassembling the compressor.

4-160

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.8 Engine Control

5

4

A

3

TI N

AM E

RI C

2

LA

1

Battery relay

2)

Battery

3)

Engine start switch

4)

Fuel control dial

6)

SA

5)

NY

1)

Start motor

Engine controller

7)

Fuel injection pump

8)

Throttle motor

9)

Shutdown device

6

9

7

8

Z ZX215-1002176

Outline ● Start and stop the engine only with the engine start switch (3). ● The controller (6) receives the signal from the fuel control dial (4) and transmits the drive signal to the throttle motor (8) to control the governor lever angle of fuel injection pump (7) and control the engine speed. ● When engine start switch (3) is turned to the OFF position, the shutdown device (9) pulls the flame-out arm on the injection pump to the “parking” position and cuts the engine fuel supply. Then, the engine stops.

Shop Manual - June 2013

4-161

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.8.1 System operation Engine startup

(Power) Fuel ctrl dial

Start motor

Lo

Hi

Lo

When it happens, the controller checks the signal voltage from the fuel control dial and sets the engine speed to the speed set by the fuel control dial.

s E

Governor motor

S L

Safety relay

s P

SW B E

B BR C Lock relay

Alternator

Drive signal

(Potentiometer singal)

Throttle On

Bat. relay

RI C

Shutdown device

P B E

M P

Start S/W

Starting relay

(Starting signal)

A

Hi

Pilot S/W

Shutdown relay

(Starting signal)

Engine

Throttle Off

● When the start switch is turned to the START position, the starting signal is transmitted to the start motor. Then, the start motor rotates to start the engine.

Controller

(Regulating signal

(Start switch ON signal)

AM E

ZX215-1002177

● The fuel control dial sends a signal voltage corresponding to the rotation angle to controller.

Engine Fuel ctrl dial

Hi

Lo

LA

Throttle On

P B E

M P

Start S/W

Starting relay SW B

S

(Starting signal) L Safety s relay P

E

B BR C Lock relay

Alternator

Drive signal

Shutdown device

s E

Governor motor

(Potentiometer singal)

The controller sends a driving signal to the throttle motor according to the signal voltage to control the fuel injection pump, and eventually controls the engine speed.

Lo

Throttle Off

TI N

Hi

(Power)

Start motor

Bat. relay

Pilot S/W

Shutdown relay

(Starting signal)

Engine speed control

Controller (Regulating signal (Start switch ON signal)

NY

ZX215-1002178

Engine shutdown

(Power) Fuel ctrl dial

Hi

Hi

Lo

s E

Governor motor

Lo

P B E Throttle On

Start S/W

Starting relay

Start motor

SW B

S

(Starting signal) L

Safety s relay P

Alternator

E

B BR C Lock relay

Bat. relay

Shutdown device

Pilot S/W

Shutdown relay

(Starting signal)

Engine

Throttle Off

SA

● When the start switch is turned to the OFF position, the shutdown device cuts off the fuel supply and stops the engine.

Controller (Regulating signal (Start switch ON signal)

ZX215-1002179

4-162

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.8.2 Components 4.8.2.1 Fuel control dial 140° 9×10°

1 Level 1

Level 10

RI C

2

A

25°

Left limit

3

AM E

4

TI N

5

6

LA b

SA

Yellow

a

b

Blue

5V

VR

c

NY

a

1)

Right limit

c

Red

0V

ZX215-1002180

Knob

4)

Ball

2)

Dial

5)

Potentiometer

3)

Spring

6)

Connector

Shop Manual - June 2013

4-163

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Function

Remark:

4.49 4.75 5(V) Voltage˄V˅ ZX215-1002181

LA NY SA 4-164

A

0.25 1.72

RI C

0

TI N

The left limit is 0%; and the right limit is 100%.

100

AM E

● When throttle voltage is beyond the area, the controller sends out alarm code and the engine runs at low idle. The area under the sloping line is the abnormality detection area.

(%)

Dial angle

● Turning of the fuel control dial changes the resistance of the sliding rheostat inside the dial and the voltage signal collected by the controller. The controller calculates the collected signals and drives the throttle motor via signal output and controls the volume of the injection pump so that the engine can run at an optimal speed.

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.8.2.2 Controller

RI C

A

Controller

AM E

A

TYPE

TI N

USE FOR NO

SA

NY

LA

Controller port layout

ZX215-1002182

........ ........ ........ ........

................... ................... ................... ...................

A2

Shop Manual - June 2013

A1

ZX215-1002183

4-165

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Input and output signals A1

4-166

Input Input Input Input

Input Input Input Input Input

Signal name

Input/ output

NY

Signal name

SA

Travel speed switching solenoid Front pump solenoid valve Rear pump solenoid valve Swing priority solenoid valve Bucket confluence solenoid valve Boom priority 1 Boom priority 2 Motor drive signal + Motor drive signal Power ground Power ground Power ground Power ground Power supply(24V constant) Power supply(24V constant) Power supply(24V constant) Power supply(24V constant) Shop Manual - June 2013

Input/ output Input Input Input Output

A

Rear pump pressure sensor Sensor power ground Sensor power ground Sensor power Monitor CAN Low Calibrator CAN High Calibrator CAN Low Coolant temp very high R. travel pressure sensor Swing pressure sensor Bucket CURL pressure sensor Boom RAISE pressure sensor Arm IN pressure sensor Front pump pressure sensor Sensor PWR ground Sensor PWR Sensor PWR State indicator Monitor CAN High Monitor CAN Low Calibrator CAN Low Calibrator CAN shield wire Calibrator CAN High

RI C

Input Input Input Input Input

Pin No. 53 54 55 56 60 61 62 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81

TI N

Power ground Power ground Power ground Power supply(24V constant) Power supply(24V constant) Fuel level sensor Throttle position signal Engine speed signal RS232 ground RS232 receive Enable Coolant temperature sensor signal Oil temperature sensor signal Backup pilot pressure signal Fuel dial signal Engine speed signal ground RS232 send CPU mode Enable Engine oil pressure switch L. travel pressure sensor Bucket DUMP pressure sensor Boom LOWER pressure sensor Arm OUT pressure sensor

A2 Pin No. 82 88 89 97 98 99 100 104 113 114 115 116 117 118 119 120 121

Input/ output

Signal name

LA

Pin No. 1 2 3 4 5 11 15 19 22 23 24 30 31 33 34 38 41 42 43 48 49 50 51 52

AM E

A1

Input Input Input Input Input Input Input Output Output

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.9 Electrical Control System 4.9.1 Control function

A

Engine-Pump composite control function

RI C

Pump control function

AM E

Valve control function

Dual travel speed control

Electronic control system

Engine oil under-pressure alarm

Auto-deceleration/acceleration control

Engine speed calibration function

Self-diagnosis function

SA

NY

LA

TI N

Engine preheating/overheating alarm

NOTE: For detailed information about self-diagnosis function, see "Troubleshooting"

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4.9.2 Machine control system diagram Battery

Battery relay

Fuel control dial Fuse

Power ON signal

Power supply

Swing priority signal

RI C

Monitor panel

R. travel signal

Network signal

Working mode signal Travel spd select signal Auto-deceleration signal Signal monitor info

Fuel level signal Hydraulic oil temperature signal

Hydraulic oil temp sensor

2

L. travel signal

3

Boom UP signal

4

Boom DOWN signal

AM E

Signal monitor info

Fuel level sensor

1

A

Power supply

Preheating signal

Starting signal

Start switch

5

Arm IN signal

6

Arm OUT signal

7

Bucket CURL signal

8

Bucket DUMP signal Swing signal

TI N

Controller

Travel spd select signal

11 17

LA

Bucket confluence signal

9 10

R.Pump EX press. signal

NY

15

Relay

Motor drive signal

Engine speed

PPC lock signal

Engine speed sensor

Engine oil pressure Coolant temp sensor

Safety relay

Charging indicator

Throttle position feedback signal

16

Starting signal

SA

12

F. Pump EX press. signal 13 F. Pump control signal 14 R. Pump control signal

Motor

Potentiometer

Oil pressure switch Coolant temp sensor Alternator

Engine

Starting signal Starting motor

Heater relay

Elct. intake air heater

Preheating signal

ZX215-1002184

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Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

1

2

R. travel pressure sensor

3

L. travel pressure sensor

4

Boom UP pressure sensor

5

Boom DOWN pressure sensor

6

Arm IN pressure sensor

7

Arm OUT pressure sensor

8

Bucket CURL pressure sensor

9

Bucket DUMP pressure sensor

A AM E

Swing pressure sensor

11

TI N

17

PPC Basic pressure

13 12

PPC Lock solenoid valve

15 14 R. Pressure sensor

Bucket confluence solenoid valve

Swing priority solenoid valve

XBp2

Main valve

PsP

Servo

SA

F

Travel speed solenoid valve

Control valve ports

PnA2

NY

F. Pressure sensor

Proportional valve

Proportional valve

Servo

LA

16

F. Pump oil-feed device Work equipment actuator

RI C

10

PPC Valve

R

Travel motor

Main pump

Swing motor

R. Pump oil-feed device Work equipment actuator

Travel motor

ZX225-1102049

Remark: The diagram above illustrates the electrical control system. For hydraulic circuit diagram, see Hydraulic System section.

Shop Manual - June 2013

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Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.9.3 Engine and pump composite control function

Operator cab

PPC valve

Monitor

Travel

Travel

MAX Boom UP/DOWN Bucket DIG/DUMP

Arm IN/OUT Swing

MIN

MC Controller input

RI C

A

Fuel control dial

Option pressure sensor

Pressure sensor

H/S/L/B Auto-idle cancel

AM E

Alarm output

Pilot oil pressure

Travel speed swithing

Engine chamber

P1

P2

Pressure sensor

Engine Oil-feed adjustment

Pump Pump proportional pressure reduce solenoid valve

Throttle motor

CAN path

SA

NY

LA

KC controller

TI N

Main control valve

Potentiometer

Motor

R. Pump control angle F. Pump control angle

Calibrator SW

LED

Engine speed Actual throttle position feedback

MEMORYON

LED

H

S

L

Control motor

A/I DOWN

7

UP

RPW

LED

PWR resouce DC24V (Battery)

SW H

S

L

A/I

Fuel, coolant temp and others

ZX215-1002186

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Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Function

Engine torque T

● This function allows the operator to select a working mode according to the job to be performed and change engine power output. Four different working modes are available: H, S, L and B. To select a working mode, use the working mode selector switch on the machine monitor.

H S L

RI C

A

● The main controller controls the pump so that it can absorb all the torque at the output points of the engine depending on the pump absorption torque specified for each mode, rotation set by the fuel control dial, and actual engine speed.

AM E

Engine speed N

H mode ~1600

Power (KW)

60

1600~1800 1800~2250 84

Engine speed

~1600

Power (KW)

60

115

S L

LA

S mode

TI N

Engine speed

H

Engine powerKW

Specifications

ZX215-1002193

1600~2250

Engine speed N ZX215-1002194

84

SA

Power (KW)

~2250 60

Pump deliveryQ

Engine speed

NY

L mode

H S L

Pump output pressureP ZX215-1002195

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Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Control method of each working mode

A Engine speed N ZX215-1002190

LA

TI N

Engine powerKW

AM E

● If pump load increases and pump pressure rises, engine speed drops. In this case, engine speed will rise to near the matching point, allowing the pump controller to reduce pump discharge. On the contrary, if pump load decreases and pump pressure drops, pump controller will continue to increase pump discharge until engine speed reaches the matching point.

RI C

● The matching point of H mode: rated speed 114kW/2050rpm

Engine torque T

H mode

Engine speed N

Pump deliveryQ

SA

NY

ZX215-1002191

Pump output pressureP ZX215-1002192

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Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

S mode/B mode/L mode

Mode

S

L

B

Power output rate

90%

80%

70%

Engine torque T

Power output rate of at each working mode

H S L

A

● At this time, the controller keeps the pump oil-suction torque in line with the stabling motor curve, and controls engine speed through combined control of the engine and pump.

Engine powerKW

S L

Engine speed N ZX215-1002194

Pump deliveryQ

NY SA

ZX215-1002193

H

LA

TI N

AM E

RI C

Engine speed N

H S L

Pump output pressureP ZX215-1002195

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Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.9.4 Pump control function

Fuel injection Throttle motor pump

A

R

Servo

(Control signal)

Proportional valve

LA

TI N

(Control signal)

AM E

Servo

Proportional valve

(Engine speed signal)

RI C

Speed sensor

(Throttle position feedback signal)

Lo

(Motor drive signal)

Hi

Press.sensor

F

M P

Fuel control dial

Press.sensor

Main pump

Engine

Monitor

R. Travel signal

L. Travel signal

(CANbus) Boom UP signal

Boom DOWN signal

Arm IN signal

Arm OUT signal

Bucket DIG signal

Bucket DUMP signal

SA

Swing signal

NY

Controller

ZX215-1002196

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Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.9.4.1 Electrical positive flow control

Pump 1 delivery amount Boom RAISE PPC pressure

RI C

A

Pump 1 delivery amount Arm IN PPC pressure

AM E

Pump 1 delivery amount Arm OUT PPC pressure Pump 1 delivery amount

MAX

Corresponding delivery output

LA

Bucket DUMP PPC pressure Pump 1 delivery amount

NY

Swing PPC pressure

SA

Pump 1 delivery amount

TI N

Bucket CURL PPC pressure Pump 1 delivery amount

L. Travel PPC pressure ZX215-1002197

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Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Pump 2 delivery amount Boom RAISE PPC pressure

RI C

A

Pump 2 delivery amount Arm IN PPC pressure

AM E

Pump 2 delivery amount Arm OUT PPC pressure Pump 2 delivery amount

MAX

Corresponding delivery output

Pump 2 delivery amount

LA

Bucket DUMP PPC pressure

TI N

Bucket CURL PPC pressure

Pump 2 delivery amount

SA

NY

Boom LOWER PPC pressure Pump 2 delivery amount

R. Travel PPC pressure

4-176

ZX215-1002198

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Function

RI C

SA

NY

LA

TI N

● When the work equipment is operating, the controller collects the signal of pilot pressure sensor, and determines the control discharge amount of pump 1 and pump 2 according to the pressure signal.

AM E

Operation

A

● Use the joystick pilot pressure signal directly as the hydraulic pump discharge control signal. Pilot pressure is applied on the valve stem and, on the other hand, is collected by the controller. The controller keeps the discharge amount of the hydraulic pump at the specified value of the corresponding pilot pressure according to the functional relation between the set hydraulic pump discharge amount and pilot pressure. During combined operation, the set discharge amount of each operation shall be added.

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Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.9.4.2 Constant power control Function

Operation

Q Flow

A PMax

P

Pressure

SA

NY

LA

TI N

● When the work equipment is working, the controller collects the throttle gear signal,, a constant current value is provided and pump power control is achieved.

4-178

P0

RI C

PMax

Pump P-Q curve

AM E

● Calculation of theoretical maximum discharge amount of the pump. The system applies constant power control. The two adjustor act together hydraulically, and keep two executing unit of the same specification and acting together in synchronization. The change of pump discharge is determined by the sum of operating pressure of the two hydraulic pumps P∑ . When is met, the sum of the power of the two hydraulic pumps remains constant below the power of the engine.

Shop Manual - June 2013

ZX215-1002199

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

ESS control Function

RI C

A

● Changing of the engine speed due to load change controls the pump power, and engine output can be used more efficiently. (This function can also prevent the engine from losing control when the machine is operating under harsh conditions (eg. high - altitude area).

The engine control panel controls the target operating speed of the engine.

LA

TI N

● The engine controller collects the actual speed signal from the ECM, and preforms a closed loop control with the target operating speed. Then, the controller involves the output of closed-loop control with the calculation of the solenoid valve control signal, and sends the final adjusting current signal to the pump proportional solenoid valve.

AM E

Operation

SA

NY

● The solenoid valve feeds pilot pressure oil to the pump adjustor according to the signal of the controller, and controls the pump discharge amount.

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Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.9.5 Valve control function

Swing priortity

Bucket Confluence

Main pump

Fuel injection Throttle motor pump

Press.sensor

Press.sensor

F

M P

Speed sensor

R

Servo

(Control signal)

TI N (Control signal)

LA

(Engine speed signal)

Monitor

Controller

R. Travel signal

L. Travel signal

(CANbus) Boom UP signal

Boom DOWN signal

Arm OUT signal

Bucket DIG signal

Bucket DUMP signal

Swing signal

SA

NY

Lo

Proportional valve

Proportional valve

Arm IN signal

Hi

(Motor drive signal)

Fuel control dial

(Throttle position feedback signal)

AM E

Servo

RI C

Engine

A

Main valve

Valve control function ● Bucket flow control ● Swing priority control

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ZX215-1002200

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.9.5.1 Bucket flow control Function Swash plate angle

● Control the pump swash plate angle according to the operation of bucket control lever.

A

Max

Operation

ZX215-1002201

Bucket confluence proportional valve current

750mA

300mA Bucket control lever PPC pressure ZX215-1002202

SA

NY

LA

TI N

● When the bucket control lever is operated, the controller collects the signal from the bucket DUMP pressure sensor and bucket CURL pressure sensor, and controls the bucket confluence proportional valve.

Bucket control lever PPC pressure

AM E

RI C

Min

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Structure and Function

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4.9.5.2 Swing priority control Function

A

● Pressurized oil from pump 1 bypasses bucket 1 valve spool, and flows first to swing motor valve spool to activate swing first.

AM E

TI N

● When signals from pump 1 pressure sensor, arm pressure sensor and swing pressure sensor meet the following conditions, the controller activates the solenoid valve. The solenoid valve conducts pilot pressure oil to arm flow controller and limits the alternate circuit of arm 1 valve spool. Swing valve spool first ensures swing motor power, preventing the counter acting force when the arm is retracting from affecting the positioning of the upper swing structure.

RI C

Operation

LA

Operating condition

● Swing pressure sensor: signal output available

SA

NY

● Arm pressure sensor: signal output available

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Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.9.6 Duo travel speed control

A

Travel motor

Regulator

Throttle motor

M P

SA

Travel Speed solenoid valve

R

Servo

(Control signal)

TI N

LA

NY

Lo

Main pump

F

Servo

(Throttle position feedback signal)

Hi

(Motor drive signal)

Fuel control dial

AM E

Engine Injection pump

(Control signal)

R. Travel pressure sensor

L. Travel pressure sensor

Main valve

RI C

Regulator

Monitor

Controller

(CANbus) ZX215-1002203

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Function ● Control travel mode. Operating condition ● When Hi speed travel mode on the monitor is enabled.

A

Operation

AM E

TI N

● When the controller receives the signal from the travel pressure sensor under the conditions below, it activates the solenoid valve. Then, the solenoid valve conducts pilot pressure oil to the swash plate angle control valve of the travel motor, and reduces the swash plate angle to increase travel speed.

RI C

● When the travel mode is set at LO speed, the swash plate angle of the travel motor is the largest, and travel speed is low.

Remark:

SA

NY

LA

When one side of the tracks is lifted off the ground by the work equipment and rotating, pressure at one side of the pump increases, which makes the lifted track rotate very fast. When the machine is traveling under Hi speed mode, even if work equipment is being operated (work equipment pressure sensor is switched ON), travel mode remains in Hi travel mode.

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Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.9.7 Engine preheating/overheating alarm

Start switch

Heat Main valve

Main pump F

Engine Throttle motor

LA

Monitor

(Control signal)

Servo

Controller

NY

(CANbus)

Servo

(Control signal)

Lo

TI N

Hi

(Motor drive signal)

Fuel control dial

(Throttle position feedback signal)

M P

R

AM E

Coolant tempe sensor

RI C

A

Preheat relay

Preheat s/w

SA

ZX215-1002204

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Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.9.7.1 Engine preheating Function ● Preheating control

Operating condition

RI C

TI N

● Power ON. Start key set at the HEAT position.

AM E

● This function shall be used in combination with the preheating switch located on the right armrest. Turn the engine start key counterclockwise to the HEAT position and hold on, the engine will start preheating. When released, the key will return to the OFF position automatically and preheating stops.

A

Operation

SA

NY

LA

● Preheating switch: ON

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Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.9.7.2 Engine overheating alarm Function ● When engine coolant temperature becomes excessively high (above 110°C) during operation, overheating alarm will be displayed on the monitor screen.

A

Operation

● Power ON.

TI N

● Coolant temperature above 110°C.

AM E

Operating condition

RI C

● The controller collects signal from the coolant temperature sensor. When coolant temperature rises too high, alarming information will be generated and transmitted to the machine monitor.

LA

4.9.8 Engine oil under–pressure alarm Function

SA

NY

● The engine controller collects signal from the engine oil pressure sensor. When engine speed exceeds 600 rpm, if oil pressure is too low, alarming information will be generated and transmitted to the machine monitor. The alarm indicator lights up when the monitor receives the signal.

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Structure and Function

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4.9.9 Auto deceleration/acceleration control

Right joystick Boom

Bucket

OUT IN

UP DOWN

Engine

AM E

(Potentiometer signal)

Travel lever

A R.Travel

Reverse Forward

(Motor drive signal)

Arm

DUMP CURL

L.Travel

Reverse Forward

(Throttle signal) Monitor

L R

Fuel control dial

Left joystick

RI C

Swing

Engine throttle controller

TI N

Controller

SA

NY

LA

(CANbus)

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Control lever signal

ZX215-1002205

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Function ● If all the control levers are neutralized, engine speed will drop to the medium level automatically to reduce fuel consumption and noise.

A

● If any of the levers is operated, the engine speed rises to the set level instantly.

Speed (rpm)

Set rpm

Drop 100rpm

AM E

TI N

● About 3 second after all control levers are neutralized, engine speed will drop to the first deceleration level about 100 rpm lower than the set speed. After another 3 seconds engine speed enters low speed (1400 rpm) to reduce the loss of the hydraulic system and engine wear, and reduce fuel consumption and noise. When the control lever is operated again, the engine speed rises instantly to the previous level.

RI C

Operation

3s

Operated

Deceleration (1350rpm)

less than 2 S

Unoperated

Less than 1 S Time (s) Operated

Control lever

ZX215-1002206

SA

NY

LA

● If any control lever is operated while the engine speed is kept at decelerated level, engine speed will rise instantly to the level set by the fuel control dial.

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Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.9.10 Engine speed calibration function

Bucket confluence

Swing pripority

Pressure sensor

Engine

F

DOWN

UP

RPW

LED SW H

4-190

S

L

A/I

AM E (Control signaL)

TI N R. Travel signal

A/I

L. Travel signal

L

(CANbus) Boom UP signal

S

Boom DOWN signal

H

Swing signal

LED

Controller

Arm IN signal

LED

MEMORYON

7

(Control signaL)

(Engine speed signaL)

Calibtator

SW

Servo

Monitor

Arm OUT signal

SA

NY

Lo

Servo

LA

Hi

Bucket DIG signal

(Motor drive signaL)

Fuel control dial

Speed sensor

Bucket DUMP signal

(Throttle position feedback signaL)

M P

R

RI C

Throttle motor

Injection pump

Pressure sensor

Main pump

A

Main valve

Shop Manual - June 2013

ZX215-1002207

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Function ● Set the maximum engine speed under each working mode. This set speed is the standard to control engine speed.

Operation

RI C

A

● Calibrating procedure for positive flow excavators.

2) H, S, L maximum speed calibration, and A/ I speed calibration. 3) Turn the dial on the calibrator counterclockwise to the end 4) Power OFF

AM E

1) Selection of fixing point of throttle motor soft shaft

TI N

5) Set the calibrator to "Monitor mode", power on and check the result. Remark:

LA

Memory SW up: Calibration mode; Memory SW down: Monitor mode

SA

NY

For more information, see “Engine Speed Test and Calibrate” on page 6-3.

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Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.9.11 Electrical Components 4.9.11.1 Pump pressure sensor

Signal name

RI C

No.

A

Connection diagram

Terminal C Terminal B

A

PWR +5V

B

Output

Operation

ZX305-1002066

(V)         

SA

NY

LA

● The relationship between the pressure applied on the sensor (P) and output voltage (E) is shown in the right diagram.

Sensor output voltage (E)

TI N

Terminal A

AM E

C

(MPa) 

    Oil pressure (P)



ZX215-1002209

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Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.9.11.2 Pilot pressure sensor

Connection diagram

PWR +5V

RI C

A

Signal name

A

No.

B

Terminal C Terminal B

Output

Terminal A

Operation

AM E

C

Sensor output voltage (E)

(V)         

(MPa)

SA

NY

LA

TI N

● The relationship between the pressure applied on the sensor (P) and output voltage (E) is shown in the right diagram.

ZX305-1002066





   Oil pressure (P)



ZX215-1002210

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Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

2

RI C

A

4.9.11.3 Engine speed sensor

1

Function

TI N

● The engine revolution sensor is installed to the ring gear of the engine flywheel. It electrically calculates the number of the gear teeth which pass in front of it and transmits the result to the engine controller.

AM E

ZX215-1002211

Operation

Standard value (@25°C)

LA

● Measure the resistance between terminal 1 and terminal 2 when it is in service. 2.3±0.2 kΩ

NY

● If the measured value exceeds the standard value, replace the sensor.

SA

CAUTION

● If the engine speed sensor is not tightened to the specified torque, the sensor may send out no signals. Tighten the engine speed sensor to the specified torque.

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Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.9.11.4 Coolant temperature sensor 2

1)

Sensor

2)

Connector

ZX215-1002212

AM E

RI C

A

1

Function

LA

TI N

● The output resistance of the engine coolant temperature sensor changes with the coolant temperature. The controller collects and processes coolant temperature signals and works out the coolant temperature.

80Ω (Ref.)

60°C

56.3Ω

80°C

29.5±10Ω

100°C

16.5Ω

106°C

14.3±0.5Ω

120°C

10Ω(Ref.)

SA

Standard value

50°C

NY

Specifications

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Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.9.11.5 Fuel level sensor

2

3

4

Float

3)

2)

Lever

4)

Casing

Coupler

SA

NY

LA

TI N

1)

AM E

RI C

A

1

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ZX215-1002246

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.9.11.6 Oil pressure switch

2

3

A

1

RI C

Load

O-ring

2)

Sensor

3)

Connector

ZX215-1002214

TI N

1)

AM E

Pressure

Function

LA

● The oil pressure switch is installed on the outlet circuit of the oil filter. It detects oil pressure and transmits warning signals to the controller.

NY

Specifications

● Type of contact: Normally closed type

SA

● Operating pressure: 1.9kg

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Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.10 Monitoring System

CAN signal

Monitor

AM E

RI C

A

Controller

Power

TI N

Sensor

LA

Battery

SA

NY

● The state of the machine is monitored by the sensors mounted on the machine components. The controller processes the signals and transmits the signals to the monitor display, informing the operator of the machine condition. ● Information on the monitor display includes primarily:

4-198

W13053001

1. Alert information when a machine fault is detected. 2. Operating condition (coolant temperature, fuel level, etc. ) ● The machine control system can be operated using the switches and keys on the monitor panel.

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.10.1 Machine monitor

$

F1

F2

F3

Esc

F4

F5

TI N

Enter

AM E

RI C

A

%

Outline

LA

● The monitor displays various kinds of items and is used by the operator to select a working mode.

WX215-1204002H

● When the monitor is turned on, blinking strips may appear on the LCD screen. This is normal.

NY

● The monitor has a CPU which processes, displays, and outputs information.

SA

● The monitor has an LCD (Liquid Crystal Display) screen. NOTE:

● The LCD may have black spots (which do not light up) or bright spots (which stay on). Products having 10 or less black or bright spots conform to the product specification; such condition is quite normal. ● Continuous operation of the monitor may cause the LCD to display bright blue spots on a black background; it is quite normal.

Input and output signals No.

Signal name

Input/output

1

Digital input A

Input

3

CAN high

4

CAN low

7

Digital input B

8

Trigger power source (24V)

9

Power source (24V)

10

Grounding

11

Digital input C

12

Grounding

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Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4.10.2 Monitor functions The front side of the machine monitor is made up of three sections: A. Warning and signal indicators

A

$

%

B. Display screen

A

C. Key pad

AM E

RI C

B

Esc

F2

F3

F4

F5

Enter

XP13031506

LA

Warning and signal indicators

F1

TI N

C

NY

● When a machine fault occurs, the warning indicator lights up, reminding the user to check and address the fault.

SA

$

4-200

%

XP13031505

Shop Manual - June 2013

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Screen display The LCD display is where monitor items are shown. This display is also the interface where most monitor operations are performed. Items on a normal operation display include: 1. Working mode indicator 2. Coolant temperature gage

A

Sany Hydraulic Excavator

6

1

4. Failure code 5. Total service hours

2

RI C

3. Fuel level gage

C

6. Function icons

10

H

AM E

7. System time (Hr: Min: Sec)



3

8. Date (YY:MM:DD)

E

F

4

9. GPS signal

5

10. Engine speed level (1 to 11)

KP

6

9 8 7

AUTO

n/min

TI N

6

(

 

LA

XP13032601

Key pad

1

F1 Esc

F2

F3

F4

F5

Enter

2

SA

NY

The key pad is composed of 5 function keys and six navigation keys.

XP13031502

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1. Function keys Functions of the five keys ( on the screen.

F1

,

F2

,

F3

,

F4

,

F5

) are indicated by the function icons above them

Function keys and icons Icon

Function

F1

AUTO

n/min

or

n/min

Home page

Select the next item; Go to the next page; Increase password value

Information Menu page Engine and Throttle Signal page, etc. Password Entry page

Save

System Time Calibration page, etc.

Lower monitor brightness

Brightness Adjustment page

A

Working mode selection

RI C

S , H L , B

Operation interface

AM E

Function key

Switch between Auto idle and Non Home page auto idle Move the cursor to the right

Password Entry page

F2

Increase monitor brightness

Brightness Adjustment page

Switch between High and Low travel speed

Home page

TI N

Information Menu page, etc.

LA

or

Enter a selected entry

Password Entry page

Confirm the validity of a password and, if it’s correct, enter the desired page. Save monitor brightness Go to “Fault Information” page Enter/Confirm

Password Entry page

SA

NY

F3

Password validation

F4

F5

Brightness Adjustment page Home page Same as Enter

Go to Brightness Adjustment page Password Entry page Go to System Setup page

Information Menu page

Go to Information Menu

Home page

Return to Home page, Information Password Entry page, etc. Menu or System Setup page Machine Configuration Calibration Save page Go to System Unlock page

Lockout Information page

NOTE: When no icon is displayed above a function key, this key is disabled.

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2. Navigation keys Navigation keys

Function

Enter

Enter/Confirm

ESC

Return

RI C

A

Select the item above (returns to the bottom item after the top item); or increase the value where the cursor blinks. Select the item below (returns to the top item after the bottom item); or decrease the value where the cursor blinks. Move the cursor to the left (returns to the right end digit after the left end digit).

AM E

Move the cursor to the right (returns to the left end digit after the right end digit).

4.10.3 Monitor operation 1. Home page

Operation

LA

TI N

The Home page is the normal operation display of the monitor. Items on this page include: truck load counter, working mode, speed level, coolant temperature, fuel level, service hours, clock, fault code, etc..

Working mode selection (1) F1

switch between S, H. L and B

6

NY

● Press mode.

Sany Hydraulic Excavator

SA

NOTE: S mode is the default working mode.



C

H

E

F

Auto-idle and Non auto-idle mode (2) ● Press F2 to switch between auto-idle and Non auto-idle mode. Auto-idle mode is indicated by

AUTO

n/min

.

Non auto-idle mode is indicated by

KP

6 n/min

(

 

AUTO

n/min

. XP13032602

NOTE: Auto-idle mode is the default mode.

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When neither of the joysticks are operated for 5 seconds, the engine enters the idling state automatically in order to save fuel and reduce noise. High and low travel speed (3)

.

Low travel speed is indicated by

.

RI C

High travel speed is indicated by

A

● Press F3 to switch between high and low travel speed.

NOTE: Default travel speed is Low.

● Press F4 to go to “Fault Information” when a fault occurs.

TI N

NOTE: When the ECU detects an error in the machine, a fault code will appear on the monitor display. The tick icon on the bottom will turn red.

AM E

Fault Information (4)

Information Menu (5)

SA

NY

LA

● Press F5 to go to the Password Entry page before accessing the “Information Menu” page.

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Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

2. Information Menu password entry A 5-digit password is required to access the “Information Menu”. You can ask your local dealer to obtain this password. Operation

A

1. Press F1 to change the number where the cursor blinks in an ascending order. You can also use or to increase or decrease the number.

RI C

Information Menu

2. Press F2 to move the cursor to the right. You can also use or to move the cursor to the left or to the right.

or

ESC

XP13031501

to return to the Home

LA

4. Press page.

F5

TI N

3. When all the five digits of the password have been entered, press F3 or Enter . If the password is correct, the display moves to the “Information Menu” page; if not, please try again.

* * * * *

AM E

NOTE: The cursor moves back to the left end side after the right end side.

Please enter the password

SA

NY

5. Press F4 on this page to go to Brightness Adjustment page.

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3. Information Menu The information menu is a list of system functions. On this page, you can select and access any of the items on the list.

Information Menu

Operation Running parameter

● Press F1 to select the item below the highlighted one. The highlighter returns to the top after the bottom item. You can also use and to move the highlighter up and down.

● Press page.

or

Enter

System time setup GPS monitoring

to access the selected en-

Engine, pump and valve parameters

F5

or

ESC

to return to the Home

TI N

● Press F4 on this page to go to the Password Entry page before accessing the System Setup page.

LA

NOTE: Once an entry on the list is highlighted, an introductory hint will appear on the bottom of the display giving a short description of the selected entry. These hints include: ● Running parameters of the engine, main pup and main valve

NY

● Fault code and description

● Throttle installation assistance

SA

● System language selection ● System time setup ● GPS monitoring information

4-206

A

System language

RI C

F2

Throttle installation

AM E

● Press try.

Fault information

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XP1251203007

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

4. Engine & Throttle Signal Select “Running Parameter” on the Information Menu page and press F2 or Enter , and the display moves to Engine & Throttle Signal page. This page is a real-time display of the running parameter of the engine and throttle.

Engine & Throttle Signal Coolant temp °C: Fuel level %:

Oil press kPa:

Operation

A

Throttle gear: F1

to go to “Pilot Pressure Signal”

Eng speed rpm:

RI C

● Press page.

Gear position V:

ESC

to return to the “Information

Throt position V:

AM E

● Press F5 or Menu”.

TI N

5. Pilot Pressure Signal

XP1251203008

LA

This page is a real-time display of the pilot pressure signal of the hydraulic system. Operation

NY

● Press F1 to go to “Main Pump and Main Valve Signal” page. ESC

to return to the “Information

Boom UP kg: Boom DOWN kg: Arm IN kg: Arm OUT kg: Bucket DIG kg: Bucket DUMP kg:

SA

● Press F5 or Menu”.

Pilot Pressure Signal

Swing kg: Travel L kg: Travel R kg:

XP2051203009

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6. Main Pump & Main Valve Signal This page is a real-time display of the main pump and main valve signals of the hydraulic system.

Main Pump & Main Valve Signal

Operation

Pump1 press kg

● Press F1 to go to “Engine & Throttle Signal” page.

Prop valve2 current mA

to return to the “Information

A

ESC

Bucket confluence valve ż

RI C

● Press F5 or Menu”.

Pump2 press kg Prop valve1 current mA

Swing priority valve ż Boom priority valve ż

AM E

Hi/Lo speed switch ż

TI N

7. Fault Information

LA

Select “Fault Information” on the Information Menu page and press F2 or Enter , and the display moves to Fault Information page. This page lists important machine fault information. Operation

XP2051203010

Fault Information Current fault code:XXX XXX: XXX: XXX: XXX: XXX: XXX:

to go to the next page. ESC

XXX: XXX:

to return to the “Information

XXX: XXX: XXX: XXX:

SA

● Press F5 or Menu”.

XXX:

NY

● Press

F1

XXX: XXX: XXX: XXX:

XP13041501

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8. Throttle Installation Select “Throttle Installation” on the Information Menu page and press F2 or Enter , and the display moves to Throttle Installation page. This page displays throttle installation assistance function.

Throttle Installation

Current gear N

Operation

A

Eng speed rpm 1200 ?

● Press F2 to switch between auto-idle and full speed.

● Press Menu”.

RI C

to select high or low travel

● For machines equipped with SYFCS controllers, press F4 to switch between rpm (blue) and rpm (red). F5

Throttle position V

or

ESC

to return to the “Information

AM E

● Press speed.

F3

Gear position V

rpm

AUTO

n/min

XP2051203013

9. System Language

LA

TI N

NOTE: For machines equipped with SYFCS controllers, when engine speed calibration is not successful, a question mark will appear.

● Press

F2

to select 中文.

● Press

F3

to select English.

● You can also use or tem language on the list. ● Press F5 or Menu”.

ESC

System Language

Ё᭛㋏㒳 English Systems

SA

Operation

NY

Select “System Language” on the Information Menu page and press F2 or Enter , and the display moves to this page.

to select a sys-

to return to the “Information

Ё᭛

(QJ

XP2051203014

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10. System Time Setup Select “System Time Setup” on the Information Menu page and press F2 or Enter , and the display moves to this page. You can set system time on this page.

System Time Setup

Current time and time zone: 1234·12·12 12:12:12 W

Operation

F1

or

● Press F5 or Menu”.

to move the cursor. Enter

to save adjusted time.

ESC

to return to the “Information

Use > Ĺ @ > Ļ @ > ĸ @ > ĺ @ t o adj ust syst em t i m e

XP2051203015

TI N

NOTE: When F1 or Enter is pressed, the screen displays “Setup Finished” on the bottom. If system time has been adjusted, it cannot be adjusted again until the system is re-energized.

RI C

● Press

and

Setup time and time zone: 1234·12·12 12:12:12 W

AM E

● Use

A

● Use and to change the number where the cursor blinks.

11. GPS Monitoring

Operation

ESC

to return to the “Information

SA

● Press F5 or Menu”.

NY

LA

Select “GPS Monitoring” on the Information Menu and press F2 or Enter to view this page.

Remark:

● Longitude: “E” stands for “East”, while “W” for “West”.

GPS Monitoring Longitude ° ˖ Latitude °˖ Elevation m: Speed Km/h: Satellite No.: Comm index˖ S/N ratio 1˖ S/N ratio 2˖ S/N ratio 3˖ S/N ratio 4˖

G% G% G% G%

● Latitude: “N” stands for “North”, while “S” for “South”. ● Altitude: “P” means “Above Sea Level”, while “N” means “Below Sea Level”.

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XP130426011

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

● The blue-white bars show signal-to-Noise ratio ranges from 0 to 99. ● When the altitude is nonzero and the longitude and latitude is zero, it means that the system is receiving GPS data, yet still in the process of precise positioning.

A

● GPS is normal when the signal indicator shows 1023, otherwise it is abnormal when the signal indicator shows 615.

AM E

● When the signal indication changes to 0 from 15, it is either because the GPS service is not available, or the SIM card charge is overdue, or the GPS network is abnormal.

RI C

● When the signal indication changes to 0 from 7, a connection failure occurs either in the SIM card or in the antenna.

LA

12. Brightness Adjustment

TI N

● When the signal indication changes to 0 from 31, it is because the monitoring center suspends.

Operation

NY

Press F4 on the Information Menu Password Entry page to go to Bright Adjustment page. This page is used to adjust monitor screen brightness.

Brightness Adjustment Brightness: 20%

SA

● Press F1 to decrease brightness level. The progress bar moves to the left side. Minimum brightness is 10%. ● Press F2 to increase brightness level. The progress bar moves to the right side. Maximum brightness is 100%. ● Press ● Press Menu”.

F3

F5

Tips: Use F3 to save brightness value.

to save brightness adjustment. to return to the “Information

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13. System Setup password entry Press F4 on the Information Menu page to enter the Password Entry page before accessing the System Setup page.

System Setup

Operation Please enter the password

A

1. For password entry method, see Information Menu Password Entry page.

F5

or

ESC

to return to the Home

AM E

3. Press page.

RI C

2. When all the five digits of the password have been entered, press F3 or Enter . If the password is correct, the display moves to the “System Setup” page; if not, please try again.

XP130426012

TI N

NOTE: Contact your local dealer to obtain this password. 14. System Setup

LA

This page is used to set up machine configuration. Operation

SA

NY

● Press F1 to select the item below the highlighted one. The highlighter returns to the top after the bottom item. You can also use and to move the highlighter up and down. ● Press try.

● Press page.

F2

F5

or

Enter

or

System Setup

Machine configuration Service hour setup Machine configuration setup Hydraulic oil temperature

to access the selected en-

ESC

to return to the Home

XP2051203016

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15. Machine Configuration password entry Select Machine Configuration on the System Setup list and press F2 or Enter , and the display moves to the Password entry page before accessing the Machine Configuration page.

System Setup

Please enter the password

A

Operation

ESC

to return to the “System

16. Machine Configuration

XP13060801

TI N

3. Press F5 or Setup” page.

AM E

2. When all the five digits of the password have been entered, press F3 or Enter . If the password is correct, the display moves to the “Machine Configuration” page; if not, please try again.

RI C

1. For password entry method, see Information Menu Password Entry page.

LA

You can view machine configuration information on this page. Operation ESC

to return to the “System

NY

● Press F5 or Setup” page.

Machine Configuraiton

Machine model: Machine No.:

SA

Engine model: Hydr system model: Controller model:

XP13041502

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17. Service Hour Setup password entry Select “Service Hour Setup” on the System Setup list and press F2 or Enter , and the display moves to the Password entry page before accessing the Service Hour Setup page.

System Setup

Operation

Please enter the password

ESC

to return to the “System

RI C XP13060802

TI N

3. Press F5 or Setup” page.

AM E

2. When all the five digits of the password have been entered, press F3 or Enter . If the password is correct, the display moves to the “Service Hour Setup” page; if not, please try again.

A

1. For password entry method, see Information Menu Password Entry page.

18. Service Hour Setup

LA

This page is used to set up machine service hours. Operation

● Use

F1

or

to move the cursor.

Enter

to save adjusted time.

SA

● Press

and

NY

● Use and to change the number where the cursor blinks.

● Press F5 or Setup” page.

ESC

Current service hour 100 h 50 m Setup service hour 100 h 50 m

to return to the “System Use >Ĺ@>Ļ@>ĸ@>ĺ@ to adjust service hour

NOTE: When F1 or ENTER is pressed, the screen displays “Setup Finished” on the bottom. If system time has been adjusted, it cannot be adjusted again until the system is reenergized.

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Service Hour Setup

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XP2051203021

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

19. Machine Configuration Setup password entry Select “Machine Configuration Setup” on the System Setup list and press F2 or Enter , and the display moves to this Password entry page.

㋏㒳䆒㕂

䇋䕧ܹᴎ఼䜡㕂䆒ᅮᆚⷕ˖

A

Operation

ESC

to return to the “System

XP13060803

SA

NY

LA

TI N

3. Press F5 or Setup” page.

AM E

2. When all the five digits of the password have been entered, press F3 or Enter . If the password is correct, the display moves to the “Machine Configuration Setup” page; if not, please try again.

RI C

1. For password entry method, see Information Menu Password Entry page.

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20. Machine Configuration Setup This page is used to set up machine configuration after installation of the monitor. Machine Config Setup

Operation F1

to change machine model.

● Press

F2

to change engine model.

F4

to change hydraulic system

Hydraulic model:

RI C

● Press

F3

Engine model:

Control model:

to change controller model.

● Press F5 to save machine configuration. The screen displays “Setup finished. Please re-energize the system.” ● Press Enter to move the cursor between different parts in the machine number.

Machine No.:

Use>Ĺ@>Ļ@>ĸ@>ĺ@ to set up machine number

AM E

● Press model.

Machine model:

TI N

● Use and to increase and decrease the selected machine number by 100 each time.

LA

● Use and to increase and decrease the selected machine number. One quick pressing increase or decrease the number by 1. Long pressing increase or decrease the number in a quicker pace.

to return to the “System Setup”

NY

ESC

SA

● Press page.

4-216

A

● Press

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Mach Eng

Hydr

Cont XP13041503

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

Remark: The machine serial number is composed of 4 parts: 1) Production year, 2) Product code, 3) Tonnage code, 4) Alteration code, 5) Serial number, and 6) Tail number “8”.

A

1) Press Enter to move the cursor to different part (Production year, Product code and Serial number) in the machine number.

AM E

3) When the cursor moves to Tonnage code, press and to increase or decrease tonnage code by 1 each time; or press and to increase or decrease tonnage code by 100 each time.

RI C

2) When the cursor moves to Production year and Alteration code, press and to increase or decrease Production year and Alteration code by 1 each time.

LA

TI N

4) When the cursor moves to Serial number, press and to increase or decrease this number by 1 each time. Long pressing to change the number in a quick pace. Press and to increase or decrease this number by 100 each time.

SA

NY

5) The machine number has 4 adjustable digits. Use and to switch between the four digits, and use and to change the value on a digit. The value of the first digit from the left could be any numbers from 0 to 9 and any letters from A to Z; the value of the rest three digits could only be any number from 0 to 9. When the number exceed 9999, capital letter from A to Z will have to be used. A, B, C, D, E ... means respectively 10000, 11000, 12000, 13000, 14000, 15000 .... For example: 10000 will be written as A000; 11020 as B020, 12999 as C999.

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21. Hydraulic Oil Temperature Select “Hydraulic Oil Temperature” on the System Setup list and press F2 or Enter , and the display moves to this page.

Hydraulic Oil Temp

Operation

Hydraulic Oil Temp:

to return to the “System

A

ESC

SA

NY

LA

TI N

AM E

RI C

● Press F5 or Setup” page.

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XP2051203028

Structure and Function

SY195/205/215/225C9 Crawler Hydraulic Excavator

22. Lockout Information (Level 1) This display indicates that the machine has entered lockout state (level 1). Lockout Information

Operation ● Press

F5

to enter “System Unlock” page.

Macine model: Machine No.:

RI C

Current time:

A

Machine state: Lockout (1)

NOTE: Contact your local dealer to unlock the machine when the system is locked.

System locked

TI N

AM E

Contact manufacturer to unlock system

XP13041504

30. Lockout Information (Level 2)

Operation ● Press

F5

LA

This display indicates that the machine has entered lockout state (level 2).

to enter “System Unlock” page.

Lockout Information

Macine model:

NY

Machine No.:

SA

NOTE: Contact your local dealer to unlock the machine when the system is locked.

Machine state: Lockout (2) Current time:

System locked Contact manufacturer to unlock system

XP13041505

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SY195/205/215/225C9 Crawler Hydraulic Excavator

BSLAN AYNL AT K IN PAA ME G RI E CA

Structure and Function

4-220

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RI C

Standard Values

A

Standard Values

SY195/205/215/225C9 Crawler Hydraulic Excavator

5 Standard Values

SA

NY

LA

TI N

AM E

5.1 Standard Values of Engine - related Parts............................................................... 5-3 5.2 Standard Values of Chassis-related Parts ............................................................... 5-4

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5-1

Standard Values

SA

NY

LA

TI N

AM E

RI C

A

SY195/205/215/225C9 Crawler Hydraulic Excavator

5-2

WARNING

Read and understand all safety precautions and instructions in this manual before reading any other manuals provided with this machine and before operating or servicing the machine. Also read the safety information on machine decals before performing any operations. Failure to do so can cause machine damage, personal injury or death.

Shop Manual - June 2013

Standard Values

SY195/205/215/225C9 Crawler Hydraulic Excavator

5 STANDARD VALUES 5.1 Standard Values of Engine - related Parts Std. value for new machine

Permissible value

High Idling

rpm

2,060 ± 70

2,060 ± 70

Engine Speed Low Idling

rpm

1,050 ± 50

1,050 ± 50

rpm

2,000

kPa {mmH2O}

Min. 133 {Min. 1,000}

Min. 133 {Min. 1,000}

Max.25

35

At High Idling

Bosch Index





Valve Clearance

Intake Valve

mm

0.25

0.152 ~ 0.381

Exhaust Valve

mm

0.51

0.381 ~0.762

Compression Pressure

● Oil Temp: 40~60°C

Mpa

Min. 2.41

1.69

{kg/cm²}

{Min. 24.6}

{17.2}

Blow-by Pres- ● Coolant Temp: Working Range kPa sure {mmH2O} ● Arm-In Overflow: Max. rpm

Max. 0.98 {Max. 100}

1.96 {200}

High Idling

MPa {kg/cm²}

Min. 0.29 {Min. 3.0}

0.25 {2.5}

Low Idling

MPa {kg/cm²}

Min. 0.10 {Min. 1.0}

0.07 {0.7}

°C

80 ~ 110

120

mm

8.0

Min. 6, Max. 10

mm

5~8

5 ~8

Intake Pressure (Negative Pressure)

● Air Cleaner Outlet Location ● Arm-In Overflow+Max. rpm

TI N

At Sudden Acceleration

● Engine Speed 250 rpm

Oil Pressure

● Full Speed Range (In Oil Pan)

NY

Oil Temp.

LA

Exhaust Color

● Deflection when pressed with finger force of 58.8 N {6 kg}

SA

Fan Belt Tension

● Between fan belt pulley and alternator belt pulley

● Between fan belt pulley and A/C Comprescompressor belt pulley sor Belt Ten● Deflection when pressed with sion finger force of 58.8 N {6 kg}

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2,000

RI C

Rated Speed

AM E

Measurement condition

A

Unit

Item

5-3

Standard Values

SY195/205/215/225C9 Crawler Hydraulic Excavator

5.2 Standard Values of Chassis-related Parts Categ.

Item

Measurement condition

Unit

Std. value for new machine

Permissible value

2,030 ± 50

2,030 ± 50

● Arm-in relief condition ● Engine running at high idle

Speed when auto deceleration is oper- ● Auto idling switch on ated ● All control levers neutral

11.5 ± 0.5

11.5 ± 0.5

DOWN

mm

9.5 ± 0.5

9.5 ± 0.5

IN

mm

11.5 ± 0.5

11.5 ± 0.5

OUT

mm

9.5 ± 0.5

9.5 ± 0.5

DIG/DUMP

mm

9.5 ± 0.5

9.5 ± 0.5

mm

9.5 ± 0.5

9.5 ± 0.5

mm

9.5 ± 0.5

9.5 ± 0.5

mm

85 ± 10

85 ± 10

mm

85 ± 10

85 ± 10

mm ● Max. reading at stroke end (except mm lever play in NEUTRAL position) mm ● Engine stopped Work Equipmm ment ● Slightly push the

85 ± 10

85 ± 10

85 ± 10

85 ± 10

115 ± 12

115 ± 12

Max. 15

Max. 20

Max. 20

Max. 25

TI N

Spool Stroke

● Engine stopped

Swing control valve

Travel (L&R) Forward & Reverse

Travel control valve

Swing control lever

● Control lever grip at center

NY

Travel control lever

SA

Control Lever stroke

Bucket control lever

● Engine stopped

LA

Arm control lever

Play of control lever

control lever. Stop pushing when resistance is felt.

Stroke

● Max. reading at

stroke end.

5-4

1,400 ± 100

mm

Bucket control valve ● See Control valve.

Boom control lever

1,400 ± 50

UP

Boom control valve Arm control valve

rpm

A

● Heavy-load operating mode (H)

RI C

2 pumps at relief

● Hydraulic oil temperature: Within operational range rpm ● Engine running at high idle

AM E

Engine Speed

● Engine coolant temperature: Within operational range

Shop Manual - June 2013

mm

Standard Values

Boom control lever Arm control lever Bucket control lever Swing control lever Travel control lever Travel control pedal

Measurement condition

● Hydraulic oil temp: Within operational range ● Engine running at high idle

N {kgf}

● Control lever grip at center ● Pedal at tip ● Max. reading at stroke end

● Engine running at high idle ● Working mode: H

AM E

● Hydraulic oil temp: Within operational range Unloaded pressure

Unit

Std. value for new machine Max. 19.6 {Max. 2.0} Max. 19.6 {Max. 2.0} Max. 15.6 {Max. 1.6} Max. 15.6 {Max. 1.6} Max. 30.4 {Max. 3.1} Max. 93.1 {Max. 9.5}

Permissible value Max. 24.5 {Max. 2.5} Max. 24.5 {Max. 2.5} Max. 21.6 {Max. 2.2} Max. 21.6 {Max. 2.2} Max. 39.2 {Max. 4.0} Max. 107.8 {Max. 11}

0~1.0 {0~10}

0~2.0 {0~20}

34.3 ± 1.0 {350 ± 10} 34.8 ± 1.0 {355 ± 10}

33.3 ~ 35.3 {340 ~ 360} 33.3 ~ 36.8 {340 ~ 375}

34.8 ± 1.0 {355 ± 10}

33.3 ~ 36.8 {340 ~ 375}

25.5 ± 1.0 {261 ± 10}

24.5 ~ 27.5 {250 ~280}

33.4 ± 1.0 {342 ± 10}

32.4 ~ 34.4 {330 ~ 351}

3.9 ± 0.2 {40 ± 2}

3.7 ~ 4.1 {37 ~ 41}

A

Item

RI C

Categ. Operating Force of Control Lever/ Pedal

SY195/205/215/225C9 Crawler Hydraulic Excavator

● Hydraulic pump output pressure ● Hydraulic oil temp: Within operational range

Arm relief

● Operate corresponding control lever after engine runs at high idling speed.

TI N

Boom relief

● Hydraulic pump output pressure with all measurement circuits relieved MPa ● Hydraulic oil temp: Within operational {kg/cm²} range

NY

Swing relief

LA

● Working mode: H Bucket relief

Travel relief

SA

Hydraulic Pressure

● All control levers in neutral position

● Operate corresponding control lever after the engine runs at high idling speed. ● Working mode: H

● Hydraulic pump output pressure with all measurement circuits relieved ● Hydraulic oil temp: Within operational range

Control circuit ● Engine running at high idle source pres● Self pressure reducing valve output sure pressure with all control levers in NEUTRAL position

Shop Manual - June 2013

5-5

Standard Values

Categ.

SY195/205/215/225C9 Crawler Hydraulic Excavator

Item

Measurement condition

Unit

Std. value for Permisnew machine sible value

● Hydraulic oil temp: Within operational range Max. 100 (—)

Max. 130 (—)

3.1 ± 0.3

Max. 3.7

RI C

● Engine running at high idle

Swing brake angle

● Working mode: H

Deg. ● Swing circle misalignment amount when stopping mm after one turn

4.4 ± 0.4

Max. 5.5

27 ± 3.5

Max. 30

0

0

Max. 5

Max. 10

51.3 ± 5.1

46.2 - 60.4

28.0 ± 1.4

26.6 - 31.4

Time taken to start swing

● Working mode: H

A

● For measuring posture see Swing 1. ● Hydraulic oil temp: Within operational range 90° sec. ● Engine running at high idle

● For measuring posture see Swing 1.

AM E

● Time required for passing points 90°and 180° sec. 180° from starting point

● Engine running at high idle

Time taken to swing

● Working mode: H

● Time required for 5 turns after making initial 1 turn

sec.

TI N

Swing

● Hydraulic oil temp: Within operational range

● For measuring posture see Swing 1.

● Hydraulic oil temp: Within operational range ● Engine stopped

● Keeping the upper structure transverse on a grade of 15°. For more information see Swing 2. mm

LA

Hydraulic drift

● Notching a mating mark on inner and outer races of the swing circle

● Engine running at high idle ● Swing lockout switch: ON

SA

Motor leakage

NY

● Mating mark misalignment amount during 5 min. ● Hydraulic oil temp: Within operational range ml/ min

Travel

● Leakage amount for 1 minute during swing relief ● Hydraulic oil temp: Within operational range Lo

Travel speed (unloaded)

● Engine running at high idle ● Working mode: H ● Time required for track shoes to make 5 Hi turns after making one initial idle turn ● For more information on measuring posture see Travel 1.

5-6

Shop Manual - June 2013

sec.

Standard Values

Measurement Condition

● ● ● ● ● ●

Hydraulic oil temp: Within operational range Engine running at high idle Working mode: H Travel Speed: Low mm Hard level ground Amount of deviation (χ) while traveling 20m after initial 10m trial run For measuring posture see Travel 2/3. Hydraulic oil temp: Within operational range Engine stopped Park the machine on a grade of 12°, with the sprocket mm in the downhill direction Measure the sliding distance for 5 minutes For measuring posture see Travel 4.

27.2

mm

Max. 600

Max. 900

mm

Max. 20

Max. 27

mm

Max. 20

Max. 20

mm

Max. 45

Max. 45

TI N

AM E

13.6

Hydraulic oil temp: Within operational range Flat and level ground Bucket full of earth or with rated load (0.8m³: 1,440 kg) Boom horizontal, arm fully retracted and bucket cylinder fully extended Engine stopped Work equipment control lever in neutral position Measure total amount of falling for 15 min. by measuring the falling every 5 min. immediately after initial setting ● Bucket tip lower distance ● Boom cylinder: Cylinder retracting distance ● Arm cylinder: Cylinder extending distance ● Bucket cylinder: Cylinder retracting distance For measuring posture see Work Equipment 1.

NY

Bucket cylinder

11.5~15.5

0

LA

Leakage of travel motor Bucket tips

13 ± 2.5

0

● ● ● ●

SA

17.5~22.5

Max. 900

Hydraulic oil temp: Within operational range Engine running at high idle Traveling with the sprocket locked mm Oil leakage amount for one minute with traveling in relief condition



20 ± 2.5

Max. 800

● ● ● ●

● ● ●

Std. value for Permisnew machine sible value

RI C

Hydraulic oil temp: Within operational range Lo Engine running at high idle Working mode: H sec. Level ground Time required for traveling 10m after 10m trial run Hi For measuring posture see Swing 2.

● ●

Arm cylin- Boom der cylinder

Hydraulic drift

Work Equipment

Unit

● ● ● ● ● ●

● ● ● ●

Hydraulic drift

Travel

Deviation

(Actual run)

Item

Travel speed

Cat.

A

SY195/205/215/225C9 Crawler Hydraulic Excavator

Shop Manual - June 2013

5-7

Standard Values

Categ.

Item

SY195/205/215/225C9 Crawler Hydraulic Excavator

Measurement condition

Unit

Std. value for Permisnew machine sible value

● Hydraulic oil temp: Within operational range Boom

● Engine running at high idle ● Working mode: H ● Time required for the bucket to raise from the ground to its stroke end

UP

sec.

IN

sec.

● For measuring posture see Work Equipment 3.

TI N

● Hydraulic oil temp: Within operational range

AM E

● Working mode: H ● Time required from dumping stroke end to digging stroke end

Max. 4.8

A

● Engine running at high idle

RI C

● Hydraulic oil temp: Within operational range

Arm

Work Equipment Speed

Work Equipment

● For measuring posture see Work Equipment 2.

3.4 ± 0.4

2.8 ± 0.4

Max. 4.5

OUT

sec.

2.3± 0.3

Max. 3.5

DIG

sec.

2.3 ± 0.4

Max. 3.4

sec.

1.6 ± 0.3

Max. 2.3

● Working mode: H

● Time required from dumping stroke DUMP end to digging stroke end

LA

Bucket

● Engine running at high idle

SA

NY

● For measuring posture see Work Equipment 4.

5-8

Shop Manual - June 2013

Standard Values

SY195/205/215/225C9 Crawler Hydraulic Excavator

Item

Measurement condition

Unit

Max. 1.2

A

Max. 1.0

RI C

Hydraulic oil temp: Within operational range Engine running at low idle Working mode: H Time required from maneuvering the joystick to the moment that the bucket reaches the sec. ground and begins to push the machine upward, within 50mm off the ground ● For measuring posture see Work Equipment 5.

Std. value for Judgement new machine criteria

● ● ● ●

Hydraulic oil temp: Within operational range Engine running at low idle Working mode: H Average time required for operating the consec. trol lever back and forth till the arm starts to move ● For measuring posture see Work Equipment 6.

AM E

● ● ● ●

Hydraulic oil temp: Within operational range Engine running at low idle Working mode: H Average time required for operating the consec. trol lever back and forth till the arm starts to move ● For measuring posture see Work Equipment 7.

Max. 2.0

Max. 2.8

Max. 1.0

Max. 3.6

5

20

10

50

Max. 200

Max. 220

LA

TI N

● ● ● ●

NY

Central Swivel Cylinders Joint work equipment and travel

Amount of deviation in simultaneous operation of

Performance in Combined Operations

SA

Internal Leakage

Bucket

Arm

Time Delay

Work Equipment

Boom

Cat.

● Hydraulic oil temp: Within operational range ml/ ● Engine running at high idle ● Leakage amount for one minute with cylinder min or travel measured at relief condition

● ● ● ● ●

Hydraulic oil temp: Within operational range Engine running at high idle Working mode: H Travel Speed: Low mm Amount of deviation measured for 20 m after traveling about 10 m on a hard level ground ● For measuring posture see Travel 2.

Shop Manual - June 2013

5-9

Standard Values

SY195/205/215/225C9 Crawler Hydraulic Excavator

Machine postures for measuring (For all models) Travel 1: Travel speed (without load)

Travel 2: Travel speed (actual run), Travel deviation

TI N

Swing 1: Swing brake angle, time taken to start swing, time taken to swing

ZX215-1003005

AM E

ZX215-1003002

RI C

A

Control value: Spool stroke

NY

LA

45°

ZX215-1003003

ZX215-1003006

Travel 3: Travel deviation

SA

Swing 2: Hydraulic drift of swing

15°

x 10m ZX215-1003007

Sprocket ZX215-1003004

5-10

Shop Manual - June 2013

Standard Values

SY195/205/215/225C9 Crawler Hydraulic Excavator

Travel 4: Hydraulic drift of Travel

Work equipment 3: Arm speed

RI C

A

12°

ZX215-1003008

AM E

Work equipment 4: Bucket speed

LA

TI N

Work equipment 1: Hydraulic drift of work equipment

ZX215-1003011

ZX215-1003009

Work equipment 2: Boom speed

ZX215-1003012

SA

NY

Work equipment 5: Boom delay

ZX215-1003010

Shop Manual - June 2013

ZX215-1003013

5-11

Standard Values

SY195/205/215/225C9 Crawler Hydraulic Excavator

Work equipment 7: Bucket delay

RI C

A

Work equipment 6: Arm delay

ZX215-1003015

SA

NY

LA

TI N

AM E

ZX215-1003014

5-12

Shop Manual - June 2013

Standard Values

SA

BLNY ANLA TI KN PAAM E G RI E CA

SY195/205/215/225C9 Crawler Hydraulic Excavator

Shop Manual - June 2013

5-13

SY195/205/215/225C9 Crawler Hydraulic Excavator

BSLAN AYNL AT K IN PAA M GERI E CA

Standard Values

5-14

Shop Manual - June 2013

Testing and Adjusting

A

SY195/205/215/225C9 Crawler Hydraulic Excavator

RI C

Testing and Adjusting 6 Testing and Adjusting

SA

NY

LA

TI N

AM E

6.1 Engine Speed - Test and Calibrate .......................................................................... 6-3 6.1.1 Testing ........................................................................................................... 6-3 6.1.2 Adjusting ........................................................................................................ 6-3 6.2 Exhaust Gas Color - Test ......................................................................................... 6-6 6.3 Valve Clearance - Adjust.......................................................................................... 6-8 6.3.1 Testing............................................................................................................ 6-8 6.3.2 Adjusting ...................................................................................................... 6-10 6.4 Compression Pressure - Measure ..........................................................................6-11 6.5 Fuel Injection Timing - Test and Adjust .................................................................. 6-13 6.5.1 Testing.......................................................................................................... 6-13 6.5.2 Adjusting ...................................................................................................... 6-15 6.6 Engine Oil Pressure - Measure.............................................................................. 6-17 6.7 Engine Speed Sensor - Adjust ............................................................................... 6-19 6.8 A/C Compressor Belt Tension - Test and Adjust ................................................... 6-20 6.8.1 Testing ......................................................................................................... 6-20 6.8.2 Adjusting ...................................................................................................... 6-20 6.9 Swing Bearing Clearance - Measure ..................................................................... 6-22 6.10 Track Tension - Test and Adjust ........................................................................... 6-24 6.10.1 Testing........................................................................................................ 6-24 6.10.2 Adjusting .................................................................................................... 6-25 6.11 Hydraulic Pressure in Hydraulic Circuits - Test and Adjust .................................. 6-26 6.11.1 Measuring .................................................................................................. 6-26 6.11.2 Adjusting..................................................................................................... 6-28 6.12 Control Circuit Oil Pressure - Test and Adjust...................................................... 6-30 6.12.1 Testing........................................................................................................ 6-30 6.12.2 Adjusting .................................................................................................... 6-31 Shop Manual - June 2013

6-1

Testing and Adjusting

Solenoid Valve Output Pressure - Measure......................................................... 6-32 Pilot Valve Output Pressure - Measure................................................................ 6-34 Pilot Valves (Work Equipment and Swing) - Adjust ............................................. 6-36 Work Equipment Hydraulic Drift - Test ................................................................. 6-37 Residual Pressure in Hydraulic Circuit - Release ................................................ 6-40 Oil Leakage - Measure ........................................................................................ 6-41 Air in Each Component - Bleed............................................................................ 6-46

SA

NY

LA

TI N

AM E

RI C

A

6.13 6.14 6.15 6.16 6.17 6.18 6.19

SY195/205/215/225C9 Crawler Hydraulic Excavator

6-2

WARNING

Read and understand all safety precautions and instructions in this manual before reading any other manuals provided with this machine and before operating or servicing the machine. Also read the safety information on machine decals before performing any operations. Failure to do so can cause machine damage, personal injury or death.

Shop Manual - June 2013

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

6 TESTING AND ADJUSTING 6.1 Engine Speed - Test and Calibrate Engine speed calibrator

1

Part Number

Part Name

B249900001206 Engine Speed Calibrator

A

ID

Testing Items: 1. Engine speed at low idle

AM E

Start the engine and keep the engine running until engine coolant temperature rises within the operational range. Key in the code on the monitor and check if the engine speed is normal in each throttle position.

RI C

6.1.1 Testing

TI N

2. Engine speed at fuel control dial position 11 (H and S modes)

LA

3. Engine speed at relief, with fuel control dial placed at position 11 (H and S modes) 4. Engine speed at auto idle

NY

6.1.2 Adjusting

SA

Adjust the fixing point of the flexible shaft of the throttle motor. 1. Connect the calibrator with the chassis harness.

ENG. Shaft bracket

2. Push the memory switch of the calibrator down to the OFF position. 3. Turn the start switch of the machine to the ON position.

Tighten Lock nut Loosen

Min. throttle

4. Start the engine. Check if engine speed is within 1100±50 rpm range. (Throttle voltage at speed level 1 is 1.3±0.03V)

Shop Manual - June 2013

Max. throttle

Flexible shaft

WX215-1304008

6-3

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

5. Tighten the fixing position of the flexible shaft when engine speed is lower than 1050 rpm; loosen the fixing position of the flexible shaft when engine speed is higher than 1150 rpm. 6. Shutdown the engine. Speed calibration steps:

RI C

2. Push the memory switch of the calibrator down to the OFF position. Turn the start switch of the machine to the ON position.

A

1. Connect the calibrator with the chassis harness. Memory s/w

3. Start the engine. Engine speed “XXXX” will be displayed on the screen display of the calibrator. Press the H button and hold it, the screen will display “E. XXXX”.

H

H

5. Shut off the engine.

H button

LA

NOTE:

SA

NY

In order to make sure speed calibration is successful, deactivate auto-idle mode after the calibration process and check the idling speed at each speed level. If excessive variation is found between the real speed and the target speed, try automatic speed calibration once again.

6-4

S

S

L

L

A/I DOWN

UP

RPM

A/I

Analog output

TI N

4. When automatic speed calibration is completed, the screen display of the calibrator will change from “E. XXXX” to “XXXX”.

AM E

MEMORY ON

Shop Manual - June 2013

A/I button WX215-1304009

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

Speed (rmp)

S1

1100

H1

1100

S2

1200

H2

1200

S3

1300

H3

1300

S4

1500

H4

1500

S5

1600

H5

1600

S6

1650

H6

1700

S7

1750

H7

1800

S8

1850

H8

1900

S9

1950

H9

2000

S10

2050

H10

2100

S11

2150

H11

2200

RI C

Level

AM E

Speed (rmp)

SA

NY

LA

TI N

Level

A

Engine speed reference (SY215C9)

Shop Manual - June 2013

6-5

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

6.2 Exhaust Gas Color - Test Testing tools ID

Model

Part Name

1

YDJ-2006

Smoke meter

2

SV-2TY

Opacimeter

A

CAUTION

RI C

● Do not touch any hot parts when mounting or dismounting the testing tools.

1) Put the filter paper into the smoke meter. 2) Insert the waste gas intake pipe into the exhaust pipe.

AM E

1. Measure with a smoke meter

TI N

3) Start the engine and keep the engine running until engine coolant temperature is within the operational range.

LA

4) When engine speed increases suddenly or is kept at high idle, direct exhaust gas through smoke meter to the filter paper.

NY

5) Remove the filter paper from the smoke meter. Read the smoke value through the apparatus provided.

SA

6) Remove the testing tools after measuring. Make sure the machine goes back to its normal state.

6-6

Shop Manual - June 2013

ZX215-1004002

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

2. Measure with an opacimeter

2) Open the opacimeter and preheat it for about 15 minutes.

LA

TI N

3) Start the engine and keep the engine running until engine coolant temperature is within the operational range.

ZX215-1004003

AM E

RI C

A

1) Mount the opacimeter onto the exhaust pipe by clamping it to the pipe outlet.

ZX215-1004004

NY

4) When engine speed increases suddenly or is kept at high idle, use the opacimeter to read the smoke value of exhaust gas.

SA

5) Remove the testing tools after measuring. Make sure the machine goes back to its normal state.

Shop Manual - June 2013

6-7

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

6.3 Valve Clearance - Adjust Service Standard (Unit: mm) Location

Service Item

Standard Value

Limits

Remedy



Valve clearance (engine cold)

0.4



Adjust

Tool Name and Shape

Part Number

Flat head screwdriver

Valve clearance adjustment (Carried on vehicle)

AM E

MH060008

Application

RI C

Symbol

A

Special Tools

Check and adjust valve clearance in cold state as per the following procedure:

LA

1. Remove the rocker arm cover.

TI N

6.3.1 Testing

Sight Glass

2. Turn the No.1 piston or the No.6 piston to the top dead center of compression stroke by following the procedure below.

SA

NY

● Turn the engine until the mark 16 on the flywheel aligns with the pointer on sight glass of the flywheel shell. Sight Glass

16

● Turn the No.1 piston or the No.6 piston to the top dead center of compression stroke.

Pointer

ZX215-1004009

6-8

Shop Manual - June 2013

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

NOTE:

RI C

A

When the rocker arm at the intake side and rocker arm at the exhaust side cannot be turned with hands, it is indicated that the piston has reached the top dead center of compression stroke. Turning the engine by one more turn, the top dead center of compression stroke of No.1 piston and No.6 piston interchanges.

Cylinder

1

INT EXH

2 ●



3 ○



4 ●



5 ○



6 ●



○ ○

AM E

3. When the No.1 piston is at the top dead center, adjust the valve clearance in a sequence marked by the black dot.

TI N

1) When a feeler gauge is used for such measurement, resistance to a moving feeler gauge in the clearance should be felt.

Valve clearance

LA

2) If the feeler gauge moves easily in the clearance, it is impossible to obtain accurate result.

NY

4. If the measured value is out of specification, readjustment shall be performed according to the following method.

SA

ZX215-1004007

Shop Manual - June 2013

6-9

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

6.3.2 Adjusting 1. To adjust valve clearance, loosen the locknut before adjusting the adjustment screw. Standard clearance is achieved when resistance to the feeler gauge is felt when pulling it out from the clearance.

Adjustment Screw

Locknut

RI C

A

2. After adjustment, stop the turning motion of the adjustment screw with a screwdriver, and tighten the locknut. Locknut: 16-24 N·m {1.7±2.5 kgf·m}

4. Check the clearances again with the feeler gauge. Readjustment should be made if the value is out of specification.

ZX215-1004006

Adjustment Screw

SA

NY

LA

TI N

5. When the engine is carried in vehicle, using to turn the adjustment screw will make your work easy.

Valve Clearance

AM E

3. Go on with the next step until all valve clearances marked with a black dot have been adjusted.

6-10

Shop Manual - June 2013

ZX215-1004008

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

6.4 Compression Pressure - Measure Service Standard Location

Standard Value

Limits

Remedy

Each cylinder (at 200 2550kPa {26kgf/cm²} 1960 kPa {20kgf/cm²} Compression rpm) Differential pressure pressure — Below 390 kPa {4kgf/cm²} between cylinders

Test Test

A



Service Item

Tool Name and Shape Compression pressure gauge connector

Part Number

AM E

Symbol

RI C

Special Tool

MH061460

A M14×1.5

A

Application

Measuring compression pressure

TI N

1. Reduction of compression pressure can be an indication for engine overhaul.

NY

LA

2. Check the compression pressure regularly and pay attention to its variation from time to time. In addition, in a new vehicle or when new parts are installed for replacement, the pressure may be higher due to running-in of the piston ring, valve seat, etc. The pressure will become normal as the parts wear.

SA

3. Before testing, make sure engine oil, start motor and battery are in normal condition. 4. Set the machine as per the following: 1) Preheat the engine until engine coolant temperature reaches 75~85°C. 2) Switch off all lamps and auxiliary devices. 3) Place the gear lever in a neutral position. 5. Remove the entire fuel injector.

Shop Manual - June 2013

6-11

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

6. Cover the fuel injector mounting opening with cloth. 7. Activate the start motor in order to run the engine. Check if the cloth is stained by foreign substances.

Rags Injector mounting hole

A

8. Determine the problem with the engine according to the substances (engine oil and/ or coolant) on the cloth.

CAUTION

When coolant and/or engine oil is found attached to the cloth, running the engine may cause the hot coolant and engine oil to squirt out through the mounting hole of the fuel injector. This is very dangerous. Never touch or look into the fuel injector mounting hole when the engine is running.

TI N

9. Mount the gasket and tool to the fuel injector mounting hole and fix them with the injector cap. Install the compression pressure gauge.

ZX215-1004005

AM E

2) When engine oil and coolant are found, it might be cracking of cylinder. Replace the crankcase.

RI C

1) When engine oil is found, it might be improper sealing caused by piston ring. Check the piston ring.

LA

10. Start the engine and measure the compression pressure of each cylinder. Calculate the differential pressure between the cylinders.

NY

11. When the compression pressure and the differential pressure between cylinders deviate from their limits, inject a small amount of engine oil through the fuel injector mounting hole, and measure the compression pressure again.

SA

● If the compression pressure is higher, it is probably due to worn or damaged piston ring or cylinder inner surface. ● If the compression pressure is still low, it is probably due to stuck valve or improper seating, or improperly mounted gasket of cylinder head.

6-12

Shop Manual - June 2013

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

6.5 Fuel Injection Timing - Test and Adjust Service Standard Location

Service Item

Standard Value

Limits

Remedy



Fuel injection timing (BTDC)

14°



Adjust

Tightening Torque (Unit: N·m) Parts Tightened

Tightening Torque



Union nut

24



Lock plate

3.4~4.9





Lock seat - delivery valve

39~44





Nut (used for mounting fuel injection pump)

29~39



Symbol

Tool Name and Shape

TI N

Universal Extension Rod A 14

RI C

AM E

Special Tool

Remark

A

Symbol



Part Number

Application

MH061099

Testing and adjusting the fuel injection timing

6.5.1 Testing

LA

A

SA

NY

1. Remove the injection pipe, lock plate, lock seat, retainer ring and delivery valve from the No.1 cylinder of the fuel injection pump. 2. After removal of all the parts, install the lock seat.

Injection pipe Lock Seat Retainer Ring Spring Delivery Valve

Lockplate

NOTE: The removed parts should be put into light oil in order to keep them free from dust.

ZX215-1004011

Shop Manual - June 2013

6-13

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

3. Install the prepared injection pipe onto No.1 cylinder. Keep the other end of the injection pipe downward so that fuel flowing out can be observed.

Injection pipe

RI C

A

4. Turn the crankshaft manually over 180° in the forward direction to locate No.1 cylinder in a position that is about 30° from the top dead center of compression stroke.

5. The main pump is used to transfer fuel. As the fuel flows out of the injection pipe, turn the engine manually in the forward direction.

TI N

NOTE: The engine positioning lever on the governor must be placed in the starting position.

AM E

ZX215-1004012

LA

6. When the fuel coming out of the injection pipe is about to stop, continue to turn the engine slowly until the fuel stops coming out.

Injection pipe

Priming pump

Positioning Lever ZX215-1004013

NY

7. Make sure that the flywheel mark and pointer are one degree before the fuel injection timing.

SA

Pointer

ZX215-1004014

6-14

Shop Manual - June 2013

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

NOTE: When the fuel injection timing deviates from its standard value, the following steps must be followed for adjustment.

6.5.2 Adjusting 1. Loosen the mounting nuts of fuel injection pump.

A

A: 4 nuts (on the flange)

AM E

RI C

B: 1 nut

B

TI N

A

2. Targeted at the pointer, activate the injection pump in order to adjust injection timing.

ZX215-1004015

Injection Pump

Pointer ZX215-1004016

SA

NY

LA

3. Tighten the nuts to specific torque. Measure the injection timing again.

Shop Manual - June 2013

6-15

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

4. When the injection timing is slow, move the injection pump toward the crankcase (direction C).

C

5. When the injection timing is fast, move the injection pump away from the crankcase (direction D).

D

RI C

A

Injection Pump

6. When injection timing meets the standard value, install the delivery valve, spring, retainer ring, lock seat, lock plate and injection pipe.

LA NY SA 6-16

Lock Seat

Injection pipe

TI N

7. Tighten all the parts to specific torques.

AM E

ZX215-1004017

Shop Manual - June 2013

Lockplate

ZX215-1004018

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

6.6 Engine Oil Pressure - Measure Service Standard Location — —

Service Item Engine oil pressure at 70~90°C

Standard Value

Limits

Min. speed, unloaded

145 KPa

49 KPa

Max. speed, unloaded

295 KPa~490 KPa

195 KPa

A

Tightening Torque (Unit: N·m) Part Tightened

Tightening Torque



Engine oil pressure switch

7.8~12

Symbol

Location

Part Number

Amount



Threads of pressure switch

A420300000032

As necessary

LA

TI N

1. Remove the engine oil pressure switch.

AM E

Lubricant/Sealant

Engine cold

Engine Oil Pressure Switch

NY

ZX215-1004019

2. Mount the adaptor to where the engine oil pressure switch has been removed. Mount the engine oil pressure gauge to the adaptor.

SA

Remark

RI C

Symbol

Pressure Gauge

Adaptor ZX215-1004020

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6-17

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

3. Preheat the engine until engine oil temperature reaches 70-90°C. 4. Measure respectively the unloaded engine oil pressure at minimum speed and maximum speed.

A

5. If the measured value is lower than the specified standard value, check the entire lubrication system.

RI C

6. After measuring, apply sealant to the threads of pressure switch. Tighten the pressure switch to specific torque.

SA

NY

LA

TI N

Then engine oil pressure switch must be installed when the engine is cold.

AM E

NOTICE

6-18

Shop Manual - June 2013

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

6.7 Engine Speed Sensor - Adjust

1. Screw on the sensor (1) until its end contacts with ring gear tip (2) of the flywheel. 2. Unscrew the sensor some degrees.

RI C

AM E

1

A

NOTE: Remove the engine speed sensor (1) before adjusting. Check for presence of metal chips and for damaged sensor top. Restore the sensor.

1

ZXT215-1004001

2

TI N

Degrees: 1.2~1.4 turns Adjust the clearance (a) between the sensor end and the flywheel edge to 2±0.2 mm.

LA

3. Tighten the sensor (1) with the nut (3). Nut: 49.0~68.6 N·m {5~7kg·m}

3

a ZX215-1004021

SA

NY

4. Make sure that the engine speed is displayed properly on the control panel after adjustment.

Shop Manual - June 2013

6-19

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

6.8 A/C Compressor Belt Tension - Test and Adjust 6.8.1 Testing Press the intermediate point of the belt between the drive pulley and the compressor pulley with a finger force of about 58.8 N(6kgf), and measure deflection (A) of the belt, which shall be 5~8 mm (0.20 in~0.31in).

Compressor Belt Pulley

Drive Pulley

RI C

A

A

AM E

ZX215-1004022

6.8.2 Adjusting NOTE: If the belt deflection is abnormal, adjust it according to the following procedure.

TI N

1. Loosen the bolts (1) and (2).

4 1

2. Move the compressor (3) and the bracket (4) together to adjust belt tension.

LA

3. After positioning the compressor (3), tighten the bolts (1) and (2).

2

4. Check belt tension again after adjustment.

NY

ZXT215-1004002

SA 6-20

3

Shop Manual - June 2013

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

Reference Use a tensiometer to check the compressor belt tension. Used Belt

637±108 N {65±11 kgf}

441±88.2 N {45±9 kgf}

A

New Belt

● Contact local Sany dealer and replace the belt in case of the following conditions.

TI N

● The fan belt has been stretched and little margin is left for adjustment.

AM E

● Check each belt for damage. Check the V-groove and the V-belt for wear. In addition, it is especially important to keep the V-belt free from friction with bottom of the V-groove.

RI C

NOTE:

● Cuts or cracks are found in the belt. ● Abnormal sliding or noise.

SA

NY

LA

● When a new belt is mounted, readjust the belt tension after one hour operation.

Shop Manual - June 2013

6-21

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

6.9 Swing Bearing Clearance - Measure Measuring tool Symbol

Part Number

Part Name

H

60033930

Dial gauge

RI C

A

● The following steps are to be followed when measuring the clearance of swing bearing.

● Park your machine on a level ground. Lower your work equipment to the ground. ● Do not put your hands or feet under the undercarriage during measurement.

AM E

CAUTION

TI N

1. Fix the dial gauge (H) to the track frame and apply the probe to the lower end of the outer race.

LA

2. Place the work equipment to the maximum reach position. Raise the bucket to a height that the bucket tips and the swivel table bottom are on the same level.

H

NY

At the moment, the front of upper structure lowers while the rear rises. ZX215-1004023

3. Set the dial gauge (H) to zero.

SA

4. Set the arm almost perpendicular to the ground and lower the boom until the front track shoe floats. At the moment, the front of upper structure rises while the rear lowers. 5. Read the dial gauge (H). 6. Restore the machine to the condition of

ZX215-1004024

6-22

Shop Manual - June 2013

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

step 2. Check the dial gauge (H) to see if it reads zero.

150~200mm

The value indicated by the dial gauge (H) is the clearance of the bearing.

A

For more information, see “Swing bearing” on page 4-13.

ZX215-1004025

SA

NY

LA

TI N

AM E

RI C

Repeat step 3 through step 5 if the dial gauge (H) reads a value other than zero.

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6-23

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

6.10 Track Tension - Test and Adjust 6.10.1 Testing 1. Move your machine forward for a distance that is equal to the length of track on the ground. Keep running the engine at low idle. Park your machine slowly.

3

2 a

ZX215-1004026

SA

NY

LA

TI N

● Max. clearance (a): 10~30 mm (0.4~1.2 in)

6-24

RI C

3. Measure the maximum clearance (a) between the upper surface of track and the lower edge of the straight bar.

1

AM E

NOTE: A straight angle steel bar is recommended for this purpose as it has good resistance to bending strain.

A

2. Place a straight bar on the track over idler (1) and carrier roller (2).

Shop Manual - June 2013

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

6.10.2 Adjusting ● If track tension is incorrect, make adjustment as per the following instruction.

CAUTION

RI C

A

● Do not loosen the valve over one turn. If the valve is loosened too much, the grease under high pressure may cause the valve to eject.

1) Loosen the valve (1) to discharge grease. Tighten the valve after discharging. 2) Check the track tension again as per the above method after adjustment.

AM E

1. Reduce track tension

TI N

2. Increase track tension 1) Add grease through the grease fitting (2) with a grease gun.

1

2 ZXT215-1004003

LA

2) Check the track tension again as per the above method after adjustment.

SA

NY

NOTE: Add grease until the gap (b) between the idler guide and the track frame end becomes zero. If the tension is till low, it indicates that the pins and bushings are seriously worn. Replace the pins and bushings, or remove a piece of track shoe.

b ZX215-1004027

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6-25

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

6.11 Hydraulic Pressure in Hydraulic Circuits - Test and Adjust Testing and adjusting tools ID —

Part Number

Part Name

60038932

Hydraulic Tester

B210770000084

Adaptor

RI C

A

NOTE: The hydraulic pressure in work equipment, swing and travel (hydraulic pump output) circuits can be viewed on the monitor.

CAUTION

TI N

● Lower the work equipment to the ground and stop the engine. Operate the control levers for several times to release the residual pressure in hydraulic circuits.

AM E

6.11.1 Measuring

LA

● Open the butterfly nut on the breather valve and press the relief button to release pressure in the hydraulic tank. 1. Preparatory work before measuring

NY

1) Remove the plug (1) and plug (2) for measuring the hydraulic pressure. ● Plug (1): For oil circuit of rear pump 1

SA

● Plug (2): For oil circuit of front pump

2

2) Install the priming adaptor and connect it to the hydraulic tester. ● Use an oil pressure gauge with a capacity of 40 MPa {408 kgf/cm²}.

3) Start the engine and keep it running until the hydraulic pressure rises to a point within the operational range.

6-26

Shop Manual - June 2013

ZX215-1004028

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

2. Measurement of unloading pressure 1) Start the engine. 2) Measure the hydraulic pressure when the engine is running at high idle and all control levers are in a neutral position.

RI C

A

NOTE: The hydraulic pressure indicated is the pressure when the unloading valve unloads.

1) Start the engine and move the cylinder to be measured to its stroke end.

TI N

2) Measure the hydraulic pressure when the engine is running at high idle and the cylinder is in relief condition.

AM E

3. Measurement of work equipment pressure at relief

LA

NOTE: The hydraulic pressure indicated is the pressure when the main relief valve is in relief condition.

4. Measurement of swing pressure at relief

SA

NY

1) Start the engine. Reach out the work equipment as far as possible. Lower the work equipment on the ground in order to restrict swinging. 2) Measure the hydraulic pressure when the engine is running at high idle and the swing circuit is in relief condition. NOTE: The hydraulic pressure indicated is the pressure when the swing motor relief valve is in relief condition. NOTE: The relief pressure of swing motor is lower than the main relief pressure.

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6-27

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

5. Measurement of travel pressure at relief 1) Start the engine and lock the travel mechanism. NOTE: Place the pin (1) between the sprocket and the track frame to lock the travel mechanism.

A

2) Measure the hydraulic pressure when the engine is running at high idle and the travel circuit is in relief condition.

RI C

1

NOTE: The hydraulic pressure indicated is the pressure when the main relief valve is in relief condition. When the travel circuit is in relief condition, the pressure indicated is always the pressure at high relief.

AM E

ZXT215-1004004

6.11.2 Adjusting

TI N

NOTE: The boom relief valve cannot be adjusted. 1. Adjustment of main relief pressure

LA

NOTE: If the high relief pressure is abnormal, adjust the high pressure setting of the main relief valve (3) as per the following.

3

NY

1) Disconnect the pilot hose. 2) Loosen the locknut (4). Turn the adjustment screw (5) to adjust the pressure.

ZXT225-1104002

SA

Pressure rises as the screw turns right. Pressure drops as the screw turns left. Each turn of the screw equals about: 12.5 MPa {128 kgf/cm²}

4

Locknut: 53.5±4.9 N·m {5.5±0.5 kgf·m} 5

ZX215-1004029

6-28

Shop Manual - June 2013

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

3) Check the pressure again after adjustment. Measure the pressure according to the procedure described above. ● Connect the pilot hose before measuring the pressure.

RI C

A

● Adjustment of the high pressure setting side will affect the low pressure setting side. The low pressure setting side is, therefore, to be adjusted too.

NOTE: If the swing relief pressure is abnormal, adjust the swing motor relief valve (6) as per the following.

TI N

1) Loosen the locknut (7). Turn the adjustment screw (8) to adjust the pressure.

AM E

2. Adjustment of swing relief pressure

Pressure rises as the screw turns right. Pressure drops as the screw turns left.

Locknut:

LA

Each turn of the screw equals about: 6.71 MPa { 68.4 kgf/cm²}

78-103 N·m{8.0-10.5 kgf·m}

6

7

8 ZXT225-1104003

SA

NY

2) Check the pressure again after adjustment. Measure the pressure according to the procedure described above. 7

8 ZX215-1004030

Shop Manual - June 2013

6-29

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

6.12 Control Circuit Oil Pressure - Test and Adjust Testing and adjusting tools



Part Number

Part Name

21008760

Hydraulic Tester

B210770000084

Adaptor

A

ID

RI C

6.12.1 Testing

● Lower the work equipment to the ground and stop the engine. Operate the control levers for several times to release the residual pressure in hydraulic circuits.

TI N

● Open the butterfly nut on the breather valve and press the relief button to release pressure in the hydraulic tank.

AM E

CAUTION

LA

1. Remove the plug (1) for measuring the hydraulic pressure. 2. Install the priming adaptor and connect it to the hydraulic tester.

NY

Use an oil pressure gauge with a capacity of 6 MPa{61 kgf/cm²}

SA

3. Start the engine and keep it running until the hydraulic pressure rises to a point within the operational range. 4. Measure oil pressure when the engine is running at high idle and all control levers are in a neutral position.

6-30

Shop Manual - June 2013

1

2 ZXT215-1004007

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

6.12.2 Adjusting 1. If the measurement is less than 3.5 kgf/ cm², loosen the retaining nut (2) and screw in adjusting stud (3). Watch the change of readings on the pressure gauge at the same time. Tighten the retaining nut (2) when proper pressure value is achieved.

3

ZX215-1004031

SA

NY

LA

TI N

AM E

RI C

A

2. Remove all the tools after measurement and make sure the machine returns to its normal condition.

2

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6-31

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

6.13 Solenoid Valve Output Pressure - Measure Measuring tools ID —

Part Number

Part Name

21008760

Hydraulic Tester

B210770000084

Adaptor

RI C

A

NOTE: Make sure that the initial pressure of control oil circuit is normal before measuring the output pressure of solenoid valve.

● Lower the work equipment to the ground and stop the engine. Operate the control levers for several times to release the residual pressure in hydraulic circuits.

AM E

CAUTION

TI N

● Open the butterfly nut on the breather valve and press the relief button to release pressure in the hydraulic tank.

No.

LA

1. Disconnect the hose of solenoid valve to measure the pressure at the outlet. Solenoid Valves to be Measured Solenoid valve - high/low travel speed

2

4

Solenoid valve - swing priority Solenoid valve - bucket confluence/diffluence Solenoid valve - boom priority

5

Solenoid valve - pilot lockout

SA

3

NY

1

5

4

3

2

1

A

2. Install a tee to location (A) on each solenoid valve and connect the hose. WXT215-1206001G

3. Mount the adaptor onto the tee and connect it to the hydraulic tester. Use a hydraulic tester with a capacity of 6 MPa{61 kgf/cm²} .

6-32

Shop Manual - June 2013

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

4. Start the engine and keep it running until the hydraulic oil temperature rises to a point within the operational range. 5. Run the engine at full speed. Operate the control levers to open or close each solenoid valve, and measure the pressure.

RI C

A

● The function of each solenoid valve can be checked through the monitor's monitoring function. (This is a special function of the monitor.)

High speed travel Output Pressure

OFF (de-energize)

0 {0}

ON (energize)

3.9~4.1 MPa{39~41 kgf/cm²}

TI N

Solenoid Valve

Swing priority

Output Pressure

OFF (de-energize)

0 {0}

LA

Solenoid Valve

ON (energize)

AM E

● When each output pressure reads the following values, the solenoid valve is normal.

3.0~3.9 MPa{30~39 kgf/cm²}

NY

6. Remove all measuring tools after measurement. Make sure that the machine returns to its normal condition.

SA

Table of functioning state - pilot lock solenoid valve Functioning State

Lockout control

Function

Lock

OFF

Free

ON

Shop Manual - June 2013

6-33

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

6.14 Pilot Valve Output Pressure - Measure Measuring tools ID —

Part Number

Part Name

21008760

Hydraulic Tester

B210770000084

Adaptor

RI C

A

NOTE: Make sure that the initial pressure of control oil circuit is normal before measuring the output pressure of pilot valve.

7

Oil Circuit Measured Bucket DUMP

2

Travel right

8

Arm IN

3

Arm OUT

9

Swing

4

Bucket DIG

5

Boom DOWN

6

Boom UP

No.

TI N

1

Oil Circuit Measured Travel left

No.

AM E

1. Remove the pilot pressure switch.

LA

2. Install the adaptor and connect it to the hydraulic tester.

9

NY

Use a hydraulic tester with a capacity of 6 MPa {61kgf/cm²}

SA

3. Start the engine and keep it running until the hydraulic oil temperature rises to a point within the operational range. 4. Measure the output pressure when the engine is running at high idle and all control levers of the tested circuit are in neutral position or at full stroke.

6-34

Shop Manual - June 2013

8 7

2 1 4 3 5 6 ZXT225-1104005

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

Control Lever

Hydraulic Pressure

Neutral

0{0} Close to the average initial pressure of oil control circuit (See Table of Standard Values)

Full stroke

A

NOTE: When the measured output pressure reads the following values, the pilot valve is normal.

SA

NY

LA

TI N

AM E

RI C

5. Remove all measuring tools after measurement. Make sure that the machine returns to its normal condition.

Shop Manual - June 2013

6-35

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

6.15 Pilot Valves (Work Equipment and Swing) - Adjust ● If the play of work equipment or swing control lever is excessive, make adjustment as per the following procedure. 1. Remove the work equipment and swing pilot valve assembly. 2. Remove the rubber sleeve (1).

A

2

RI C

3. Loosen the locknut (2). Screw on the disc (3) until it contacts with the four heads of plunger (4).

3

1

4. When the disc (3) is fixed, tighten the locknut (2) to specified torque. Locknut:

5. Install the rubber sleeve (1).

TI N

98~127 N·m {10~13 kgf·m}

AM E

NOTE: Do not move the plunger.

SA

NY

LA

6. Install the work equipment and swing pilot valve assembly.

6-36

Shop Manual - June 2013

4

ZX215-1004032

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

6.16 Work Equipment Hydraulic Drift - Test NOTE: If hydraulic drift exists in the work equipment cylinder, check it according to the following procedure and determine whether the failure lies in the cylinder seal or in the control valve.

A

1. Boom and bucket cylinders

RI C

1) Park your machine in an attitude as shown and stop the engine.

2) Operate the control levers so that the

ZX215-1004033

TI N

boom is in the raising position and the bucket in the digging position.

AM E

NOTE: Load the bucket fully with earth or impose rated load on the bucket.

LA

● If the lowering speed rises, the problem lies in the cylinder seal. If nothing changes, the problem lies in the control valve. ● Operate the control levers with engine start switch in the ON position.

NY

● If the pressure in accumulator drops, charge the accumulator again by running the engine for about 10 seconds.

SA

2. Arm cylinder

Shop Manual - June 2013

6-37

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

1) Park your machine in an attitude as shown. The distance between the arm cylinder and the digging stroke end is 100 mm. Stop the engine. 2) Operate the control levers in order to place the arm in the digging position.

A

● If the lowering speed rises, it is failure of the cylinder seal. If nothing changes, it is failure of the control valve.

ZX215-1004034

[Reference]

TI N

If hydraulic drift is caused by failure of the cylinder seal, the reason for lowering speed increase during the above operation is described below:

AM E

● If the pressure in accumulator drops, charge the accumulator again by running the engine for about 10 seconds.

RI C

● Operate the control levers with engine start switch in the ON position.

LA

1) If the machine is set in the above position (where the holding pressure is applied to the bottom side), the oil leaks from the bottom side to the head side. The pressure in the head side is increased.

SA

NY

2) As the pressure in the head side decreases, the pressure in the bottom side increases in order to keep it balanced. This process is repeated until balance is reached at a certain level depending on the amount of leakage. 3) When the pressure is balanced, the lowering speed decreases. If the control levers are operated according to the above procedure, the oil circuit in the head side opens to the drain circuit (while the bottom side is

6-38

Shop Manual - June 2013

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

closed by a check valve), and the oil flows to the drain circuit from the head side. As a result, the lowering speed increases. 3. Checking the pilot valve

A

While the pressure in the accumulator is high, set the hydraulic lockout control in the LOCKED/FREE position and measure the hydraulic drift respectively.

RI C

● Operate the control levers with engine start switch in the ON position.

SA

NY

LA

TI N

● If there is a difference in hydraulic drift between the LOCKED position and the FREE position, it the failure (internal fault) of the pilot valve.

AM E

● If the pressure in accumulator drops, charge the accumulator again by running the engine for about 10 seconds.

Shop Manual - June 2013

6-39

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

6.17 Residual Pressure in Hydraulic Circuit - Release CAUTION

RI C

TI N

1. Stop the engine, loosen the butterfly nut on the breather valve, and press the release button to release the pressure in hydraulic tank.

AM E

NOTE: Even if the swing motor circuit and the travel motor circuit are free from residual pressure, they will be influenced by the internal pressure of hydraulic tank. The breather valve must therefore be opened to release pressure prior to such operation.

A

● Release the residual pressure in the hydraulic circuit before disconnecting the lines between the hydraulic cylinders or between the hydraulic motor and the control valve.

2. Turn the engine start switch to the ON position and operate the control levers for several times.

LA

● The pilot lock valve must be energized. Operate the control levers with the engine start switch in the ON position.

NY

● The pressure in accumulator will be released after the control levers have been operated 2 or 3 times.

SA

3. Start the engine and keep the engine running at low idle for about 10 seconds in order to increase the pressure in accumulator. Stop the engine. 4. Repeat the above step 2 through step 3 several times.

6-40

Shop Manual - June 2013

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

6.18 Oil Leakage - Measure 1. Measure oil leakage from boom cylinder 1) Start the engine and keep it running until the hydraulic oil temperature is within the operational range. Fully extend the boom cylinder.

1

RI C

A

NOTE: Release the residual pressure in the circuits.

2) Disconnect the hose (1) on the cylinder head side and plug the hose end with a cap. NOTE: Be careful not to disconnect the hose on the cylinder bottom side.

ZXT215-1004010

AM E

See “Residual Pressure in Hydraulic Circuit - Release” on page 6-40.

TI N

3) Start the engine and apply relief pressure to the bottom side of the cylinder while the engine is running at high idle.

LA

4) Hold this condition for 30 seconds. Measure oil leakage for one minute.

SA

NY

5) Make sure that the machine returns to its normal condition after measurement.

Shop Manual - June 2013

6-41

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

2. Measure oil leakage from arm cylinder 2

1) Start the engine and keep it running until the hydraulic oil temperature is within the operational range. Fully extend the arm cylinder. NOTE: Release the residual pressure in the circuits.

RI C

A

See “Residual Pressure in Hydraulic Circuit - Release” on page 6-40.

ZXT225-1104007

NOTE: Be careful not to disconnect the hose on the cylinder bottom side. 3) Start the engine and apply relief pressure to the bottom side of the cylinder while the engine is running at high idle.

AM E

2) Disconnect the hose (2) on the cylinder head side and plug the hose end with a cap.

TI N

4) Hold this condition for 30 seconds. Measure oil leakage for one minute.

SA

NY

LA

5) Make sure that the machine returns to its normal condition after measurement.

6-42

Shop Manual - June 2013

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

3. Measure oil leakage from bucket cylinder 1) Start the engine and keep it running until the hydraulic oil temperature is within the operational range. Fully extend the bucket cylinder.

A

NOTE: Release the residual pressure in the circuits.

RI C

See “Residual Pressure in Hydraulic Circuit - Release” on page 6-40. 2) Disconnect the hose (3) on the cylinder head side and plug the hose end with a cap.

ZXT225-1104008

TI N

3) Start the engine and apply relief pressure to the bottom side of the cylinder while the engine is running at high idle.

AM E

NOTE: Be careful not to disconnect the hose on the cylinder bottom side.

3

4) Hold this condition for 30 seconds. Measure oil leakage for one minute.

SA

NY

LA

5) Make sure that the machine returns to its normal condition after measurement.

Shop Manual - June 2013

6-43

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

4. Measure oil leakage from swing motor 1) Fully extend the work equipment. Lower the bucket on the ground and raise the machine slightly. Secure machine from rotating clockwise or counter clockwise while testing. Stop the engine.

A

2) Disconnect the hose (4) and the hose (5). Plug the hose ends with caps.

4

TI N

● After the first measurement, turn the upper structure 180°and measure the leakage again in the same way.

5

AM E

● Hold the condition described in step 3) for 30 seconds. Measure oil leakage for one minute.

RI C

3) Start the engine and apply relief pressure to the bottom side of the swing motor while the engine is running at high idle. Measure oil leakage under this condition.

SA

NY

LA

4) Make sure that the machine returns to its normal condition after measurement.

6-44

Shop Manual - June 2013

ZXT225-1104006

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

5. Measure oil leakage from travel motor 1) Remove the cover of the travel motor. 2) Start the engine and lock the travel mechanism.

A

NOTE: Insert pin (1) between the sprocket and the track frame to lock the travel mechanism.

RI C

1

LA

TI N

4) Start the engine and apply relief pressure to the bottom side of the travel motor while the engine is running at high idle. Measure oil leakage under this condition.

AM E

3) Disconnect the drain hose (6) of the travel motor. Plug the hose end with a cap.

ZXT215-1004004

WARNING

ZXT215-1004014

NY

● During measurement, mis-operation of the control levers can cause serious accidents. Make sure that all signals are given correctly.

6

SA

● Hold the condition described in step 4) for 30 seconds. Measure oil leakage for one minute. ● Rotate the motor slightly. Change the positions of the valve plate and the travel motor and of the cylinder and piston. Repeat the measurement several times.

5) Make sure that the machine returns to its normal condition after measurement.

Shop Manual - June 2013

6-45

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

6.19 Air in Each Component - Bleed Air bleeding procedures

● Cleaning filter element ● Replacing return filter element ● Repairing/replacing hydraulic pump ● Removing suction piping ● Repairing/replacing control valve ● Replacing cylinder

3

Bleed air from hydraulic pump

Starting engine

Bleed air from cylinder







○ ○











● Removing cylinder piping ● Replacing swing motor



● Removing swing motor piping ● Replacing travel motor

5

6

Bleed air Bleed air from swing form travel motor motor

○ (Note)

Starting operation

○ (Note)

○ ○

○ ○









○ ○



TI N

● Removing travel motor piping

4

A

● Replacing hydraulic oil

2

RI C

Contents of work

1

AM E

Air bleeding item

LA

NOTE: Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained. 1. Bleed air from hydraulic pump

NY

1) Loosen the air bleeder (1) and check that oil oozes out through the air bleeder. 1

SA

2) Tighten the air bleeder (1) if oil is seen. Bleeder: 7.8~9.8 N·m{0.8~1.0 kgf·m}

NOTE: Run the engine at low idle for 10 minutes after bleeding the air according to the above procedure. ZXT215-1004015

6-46

Shop Manual - June 2013

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

2. Bleed air from hydraulic cylinder 1) Start the engine and keep the engine running at low idle for 5 minutes. 2) Raise or lower the boom 4 or 5 times with the engine running at low idle.

A

NOTE: Be careful not to apply relief pressure. Stop the piston when the rod is about 100 mm before stroke end.

5) Bleed air from arm cylinder and bucket cylinder by performing step 2) through step 4).

AM E

4) While running the engine at low idle, move the piston rod to the stroke end and apply relief pressure.

RI C

3) Repeat step 2) with the engine running at high idle.

SA

NY

LA

TI N

NOTE: When a new cylinder is installed for replacement, bleed the air from the new cylinder before mounting it to the work equipment. Especially the boom cylinder, once mounted to the work equipment, its piston rod is unable to reach its stroke end in lowering operation. Therefore, the air must be bled from the boom cylinder before it is mounted to the work equipment.

3. Bleed air from swing motor 1) Start the engine and run the engine at low idle. 2) Bleed air from the swing motor by turning the upper structure slowly.

Shop Manual - June 2013

6-47

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

4. Bleed air from travel motor 1) Start the engine and run the engine at low idle. 2) Loosen the bleeder (2) and check that oil oozes out through the air bleeder. 3) Tighten the air bleeder (2) if oil is seen.

A

Bleeder:

RI C

27.5~35.3 N·m{2.8~3.6 kgf·m}

2

SA

NY

LA

TI N

AM E

ZXT215-1004016

6-48

Shop Manual - June 2013

Testing and Adjusting

SY195/205/215/225C9 Crawler Hydraulic Excavator

Table of monitored items Monitored Item

Unit

Remark

Graph

High/Low Travel Speed Selection

Graph

Auto Idle Selection

Graph

Engine Speed

r / min

Pressure - Rear pump

Kg

Current - Proportional Valve (Solenoid, Front pump)

mA

Current - Proportional Valve (Solenoid, Rear pump)

mA

Pilot Pressure - Boom Raise

Kg

Pilot Pressure - Boom Lower

Kg

Pilot Pressure - Arm In

Kg

Pilot Pressure - Arm Out

Kg

Pilot Pressure - Bucket Dump Pilot Pressure - Swing Pilot Pressure - Travel Left

LA

Pilot Pressure - Travel Right

Kg

TI N

Pilot Pressure - Bucket Curl

Kg Kg Kg Kg

Bucket Confluence

ON / OFF

Swing Priority

ON / OFF

Hi/Lo Speed Switching

ON / OFF

NY

Solenoid Valve 1

RI C

Kg

AM E

Pressure - Front pump

A

Controller Mode Selection

V

Voltage - Motor Position

V

Temperature - Engine Coolant

°C

Gauge reading

Temperature - Hydraulic oil

°C

Gauge reading

SA

Voltage - Fuel Control Dial

Pressure - Engine Oil

KPa

Shop Manual - June 2013

6-49

SY195/205/215/225C9 Crawler Hydraulic Excavator

BSLAN AYNL AT K IN PAA M GERI E CA

Testing and Adjusting

6-50

Shop Manual - June 2013

RI C

Troubleshooting

A

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

7 Troubleshooting

SA

NY

LA

TI N

AM E

7.1 Points to Remember When Troubleshooting ........................................................... 7-3 7.2 Troubleshooting Procedures .................................................................................... 7-5 7.3 Connector Location and Electrical Circuit Diagram ................................................. 7-8 7.3.1 Connector location layout ............................................................................ 7-12 7.3.2 Electrical element circuit diagram (cab circuit)............................................. 7-18 7.3.3 Electrical control circuit diagram (engine circuit).......................................... 7-20 7.3.4 Electrical control circuit diagram (sensor and solenoid valve circuit) ........... 7-22 7.3.5 SWP type connector .................................................................................... 7-23 7.3.6 A/AMP type connector ................................................................................. 7-24 7.3.7 DT type connector ....................................................................................... 7-25 7.4 Failure Symptoms and Troubleshooting Codes ..................................................... 7-26 7.5 Troubleshooting with an Event Code ..................................................................... 7-28 7.6 Troubleshooting of Electrical System (E - Mode)................................................... 7-63 7.7 Troubleshooting of Hydraulic and Mechanical Systems (H - Mode) ...................... 7-93

Shop Manual - June 2013

7-1

Troubleshooting

SA

NY

LA

TI N

AM E

RI C

A

SY195/205/215/225C9 Crawler Hydraulic Excavator

7-2

WARNING

Read and understand all safety precautions and instructions in this manual before reading any other manuals provided with this machine and before operating or servicing the machine. Also read the safety information on machine decals before performing any operations. Failure to do so can cause machine damage, personal injury or death.

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

7 TROUBLESHOOTING 7.1 Points to Remember When Troubleshooting ● Stop the machine in a level ground, and check that lock pins, blocks, and parking brake are securely fitted.

A

● When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near.

RI C

● If the radiator cap is removed when the engine is hot. Hot coolant may spurt out and cause burns, so wait for the engine to cool down before starting troubleshooting. ● Be extremely careful not to touch any hot parts or to get caught in any rotating parts.

AM E

● When disconnecting wiring, always disconnect the negative (–) terminal of the battery first. ● When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. It will also cause a waste of man-hours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator.

When carrying out troubleshooting, important point is to understand the structure and function.

For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure.

LA

TI N

The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure.

SA

NY

However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: ● Parts that have no connection with the failure or other unnecessary parts will be disassembled. ● It will become impossible to find the cause of the failure.

2. Points to ask user or operator: 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before

Shop Manual - June 2013

7-3

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

3. Check before troubleshooting 1) Check the oil level. 2) Check for any external leakage of oil from the piping or hydraulic equipment.

● Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly. ● The basic procedure for troubleshooting is as follows.

A

6) Has the same kind of failure occurred before?

5. Troubleshooting

1) Start from the simple points.

RI C

the failure? When were these repairs carried out?

2) Start from the most likely points.

4) Check the stroke of the control valve spool.

3) Investigate other related parts or information.

5) Other maintenance items can be checked externally, so check any item that is considered to be necessary. 4. Confirming failure

6. Measures to remove root cause of failure ● Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.

TI N

● Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc.

AM E

3) Check the travel of the control levers.

SA

NY

LA

NOTE: When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse.

7-4

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

7.2 Troubleshooting Procedures If some phenomenon occurs on a machine that looks like a failure, identify the corresponding troubleshooting No. and proceed to the explanations for diagnosis. Follow six steps listed below to diagnose and analyze for troubleshooting, and find the causes and work out the corresponding methods. d. What kind of trouble did machine have before?

RI C

A

1. Read related technical manuals in detail. Have a knowledge of related system, principle of operation, and structure, function and technical specification of parts.

For example: Which parts have been repaired or replaced? e. What has been done after troubles take place and how about the reaction?

Before checking, ask related person, i.e. the operator for all information about the failure.

f. Will the trouble reoccur? Does the trouble occur regularly?

3. Check before starting

TI N

a. Current working condition of machine (Whether machine is operated properly).

AM E

2. Ask operator

LA

b. When troubles are found and what kind of operation does machine perform at that time?

SA

NY

c. Development of troubles (Whether troubles are becoming severer or occur for the first time.)

Before starting troubleshooting, check the operator's records on operation, maintenance and service of the machine. Understand whether related personnel has done wrong in operation, maintenance and service. Check for wrong operation and maintenance at the same time.

Shop Manual - June 2013

7-5

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

— — —

Tighten or replace

LA

NY

A

Add fuel Clean, drain Add oil Clean, drain Add oil Add oil Add water Clean or replace Replace Add oil

— — —

1. Check battery voltage (with engine stopped) 20-30V 2. Check electrolyte level — 3. Check for discolored, burnt, exposed wiring — 4. Check for missing wiring clips and hanging wiring — 5. Check for wet wires (esp. wet connectors or terminals) — 6. Check for blown or corroded fuses 7. Check alternator voltage (with engine speed at middle — or higher) After running for 8. Check operating sound of battery relay (when start several minutes: switch is turned ON or OFF) 27.5~ 29.5V —

Shop Manual - June 2013

Remedy

— — — — — — — — — —

AM E

1. Check for abnormal noise and smell 2. Check for oil leakage 3. Bleeding air

SA

Electrics, electrical equipment

1. Check for looseness, corrosion of battery terminal and wiring 2. Check for looseness, corrosion of alternator terminal and wiring 3. Check for looseness, corrosion of start motor terminal and wiring

TI N

Lubricating oil, coolant

1. Check fuel level and type of fuel 2. Check for impurities in fuel 3. Check hydraulic oil level 4. Check hydraulic oil strainer 5. Check swing drive oil level 6. Check engine oil level (in oil pan) 7. Check coolant level 8. Check dust indicator for clogging 9. Check hydraulic filter 10. Check final drive oil level

Hydraulic, mechanical Electrical equipment equipment 7-6

Criterion

RI C

Item

Tighten or replace Tighten or replace Repair Repair Bleed air Replace Add or replace Replace Repair Disconnect connector and dry Replace Replace Replace

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

5. Perform troubleshooting Conduct deep analysis and determine the cause of trouble according to the symptoms of the machine and the information displayed on the monitor.

A

Confirming that the third item above is normal, run startup check on the machine to determine the cause of failure. If the failure cannot be determined, turn off the engine and get more information from the operator.

● Failure codes may not indicate machine trouble. Temporary electrical failure can occur in controller memory, such as low battery output voltage, or open circuit in switch or sensor. Therefore, make repeated trials to erase the accumulated failure codes from the controller memory and confirm whether the failure codes are displayed after repeated trials. That is to say, "reoccurrence" of this trouble is possible. 6. Find out possible causes

RI C

4. Operate machine by yourself (trial run)

SA

NY

LA

TI N

● Never disconnect harness and hydraulic lines when the engine is running. Oil and water under high pressure and high temperature may squirt and cause personal injuries. Shut off then engine when disconnecting the harness and hydraulic lines.

AM E

Remark:

Before making a conclusion, check the most possible causes again and try to determine the root causes of troubles. Make a feasible repair scheme according to your conclusion.

Shop Manual - June 2013

7-7

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

7.3 Connector Location and Electrical Circuit Diagram Location Connector No.

Type

T-101

Terminal

1

Battery relay coil (positive)

M-2

D-1

T-102

Terminal

1

M-2

D-1

T-103

Terminal

1

M-2

D-1

T-104

Terminal

1

Battery relay coil (negative) Battery relay contact (output) Battery relay contact (input)

T-106

Terminal

1

Starting motor (B terminal)

J-6

T-107

Terminal

1

Alternator (B terminal)

K-6

T-108

Terminal

1

Preheating fuse (21#)

M-2

T-109

Terminal

1

Preheating fuse (17#)

T-110

Terminal

1

Body grounding

T-111

Terminal

1

T-112

Terminal

1

T-115

Terminal

1

T-119

Terminal

1

T-201

Terminal

1

Body grounding Preheating resistance wire terminal Starting motor grounding Body grounding (at the sides of battery) Body grounding

T-202

Terminal

1

Body grounding

X-6

K5

R

5

Horn relay

X-6

H-9

K6

R

5

Lamp relay

X-6

I-9

K8

R

5

Top lamp relay

X-6

J-9

K7

R

5

X-6

J-8



5

Battery relay

M-2

D-1

L-3

L-5

G-9 G-9

B-1

K-6 J-7

H-9

J-6

L-3

M-1

B-9

X-6

Parking relay

K3

NY

LA

M-2

M-1

Engine circuit

D-1

AM E

M-2

Cab circuit

R

5

Starting relay

X-6

L-4

KH



5

Preheating relay

Y-6

G-9

K10

R

5

Pilot valve relay

X-6

K-1

CN-106F

A

2

Junction connector

W-6

J-2

CN-142M

D

12

Intermediate connector

W-6

C-9

CN-131M

D

12

Intermediate connector

R-5

C-9

CN-302F

A

3

Intermediate connector

R-6

D-9

CN-301M

S

6

Intermediate connector

R-6

CN-132F

D

12

Intermediate connector

R-5

C-5

CN-1-110

D

6

Intermediate connector

AB-4

K-5

CN-121F

D

12

Intermediate connector

W-6

D-8

SA

KB

7-8

Shop Manual - June 2013

Sensor, solenoid circuit

A

Layout

RI C

Name of device

TI N

No. of pin

F-9

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

Location Connector No.

Type

No. of pin

CN-241M

D

12

CN-1-112

3

CN-1-111

Name of device

Intermediate connector

W-6

F-8

3

Intermediate connector

W-6

C-9

D

8

Intermediate connector

W-6

C-9

CN-7-705

D

12

Monitor panel

P-5

D-9

CN-801F

H

6

Intermediate connector

J-7

CN-445M

S

6

Intermediate connector

I-7

CN-204F

A

2

Intermediate connector

X-6

C-8

CN-412F

A

3

Intermediate connector

X-6

C-8

CN-112M

A

2

Washing motor

K-5

K-4

CN-102M

A

2

Platform lamp

CN-104M

A

2

Boom lamp (left)

CN-105M

A

2

CN-113M

A

2

CN-101M

S

CN-152M

Engine circuit

Sensor, solenoid circuit

A

Layout

Cab circuit

K-8

AM E

RI C

F-3

E-5

K-2

E-7

K-1

E-7

K-2

1

Boom lamp (right) Hydraulic oil temperature sensor Fuel level sensor

A

2

CN-613F

L

CN-661F

F-9

F-6

F-9

Intermediate connector

W-6

F-8

6

Safety relay

X-6

K-7

S

16

Intermediate connector

W-6

I-8

CN-161M

S

16

Intermediate connector

W-6

CN-115M

DF

3

Main pressure sensor (front)

I-7

F-4

CN-116M

DF

3

Main pressure sensor (rear)

I-7

F-4

CN-128M

DF

3

Arm-in pilot sensor

I-6

F-5

DF

3

Arm out pilot sensor

I-6

F-4

DF

3

Boom-up pilot sensor

I-6

F-5

DF

3

Boom-down pilot sensor

I-6

F-6

CN-124M

DF

3

Bucket-curl pilot sensor

I-6

F-6

CN-127M

DF

3

Bucket-dump pilot sensor

I-6

F-6

CN-123M

DF

3

Swing pilot sensor

I-6

CN-120M

DF

3

Travel pilot sensor (left)

I-6

F-7 F-7

CN-121M

DF

3

Travel pilot sensor (right)

I-6

F-8

CN-448M

S

2

Speed sensor

I-7

F-9

CN-307M

H

8

Top lamp switch

R-5

C-3

CN-303M

H

8

Work lamp switch

R-6

C-2

CN-305M

H

8

Washer switch

R-6

C-2

CN-126M

SA

CN-125M

LA

NY

CN-122M

TI N

I-7

Shop Manual - June 2013

7-9

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

Location Connector No.

Type

No. of pin

CN-304M

H

8

CN-104M

A

CN-306M

Name of device Layout

Cab circuit

Wiper switch

R-6

C-1

2

Horn switch

R-6

E-3

H

8

Preheating switch

R-5

CN-207F

S

12

Air conditioner unit

W-6

CN-113F

AMP

2

F. pump solenoid valve

I-7

CN-114F

AMP

2

I-7

CN-135F

AMP

2

CN-134F

AMP

2

CN-132F

AMP

2

CN-136F

AMP

2

CN-131F

AMP

2

CN-133F

AMP

2

R. pump solenoid valve Boom priority solenoid valve 2 Bucket Confluence solenoid valve Boom priority solenoid valve 1 Pilot solenoid valve Hi/Lo speed travel solenoid valve Swing priority solenoid valve

F-108

W

1

F-104

W

F-103

A

F-2

AM E

J-6

Sensor, solenoid circuit

F-1

RI C

J-6

Engine circuit

J-6

J-6

F-1 F-2 F-3 F-3

L-2 F-1

J-6

F-4

Coolant temperature sensor

J-7

F-8

1

Horn (right)

I-5

K-2

W

1

Horn (left)

I-5

K-2

CN-616F

AMP

81

Controller

W-6

A-4

CN-615F

AMP

40

Controller

W-6

A-9

CN-800M

S

2

Alternator terminal L/R

K-6

CN-7-707

AMP

2

Cigarette lighter

P-4

CN-150M

D

8

Intermediate connector

AE-3

HL

7

Radio

W-6

-

-

Fuse box

X-4

SA

PF021

LA

NY

CN-107M

TI N

J-6

CN-1-001M

A

2

Speaker (left)

AE-6

CN-1-002M

A

2

Speaker (right)

AD-7

CN-1-103M

A

2

Front right lamp

AB-6

CN-1-004M

A

2

Front left lamp

AC-5

CN-1-005

H

1

Cab lamp

AE-7

7-10

Shop Manual - June 2013

Description

S

SWP type, Yazaki

A/AMP

AMP, Japan

D

DT type, Japan

H

Hebi

HL

Hulane Connectors

L

Ling Xing Electronic Equipment

DF

Delphi, U.S.

W

AMP, Japan

Terminal

Round terminal

SA

NY

LA

TI N

AM E

RI C

Connector code

A

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

Shop Manual - June 2013

7-11

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

7.3.1 Connector location layout

CN-105M

CN-104M

CN-101M

RI C

A

8

AM E

7

TI N

6

CN-102M

LA

5

NY

4

2

SA

3

1 ZX215-1005033

A

7-12

B

C

D

Shop Manual - June 2013

E

F

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

CN-113M

CN-113F

CN-448M

F-108

T-112 CN-801F

CN-114F

T-106 CN-115M T-115

CN-116M

T-111

A

CN-445M

RI C

CN-800M T-107

AM E

CN-112M

F-104

CN-125M CN-126M

TI N

F-103

CN-124M

LA

CN-128M

CN-127M CN-123M

NY

CN-122M CN-121M CN-120M

SA

CN-131F CN-132F CN-133F CN-134F CN-135F

CN-136F

ZX215-1005034

G

H

I

J

K

Shop Manual - June 2013

L

M

7-13

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

CN-307M

CN-306M

CN-132F

CN-305M CN-304M CN-303M

9

CN-104M CN-302

8

A

CN-131M

RI C

CN-301M

AM E

7

CN-7-705

LA

5

TI N

6

4

NY

CN-7-707

SA

3

2

1 ZX215-1005035

N

7-14

O

P

Q

Shop Manual - June 2013

R

S

T

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

CN-661F

CN-161M

CN-1-111

CN-152M

CN-1-112

T-201

CN-241M

T-202

K5

CN-121F

K6 K10 K3

A

CN-142M

RI C

K7 K8 CN-613F

AM E

CN-615F CN-616F

TI N

KH

NY

LA

CN-412F

SA

CN-204F

PF021

CN-207F CN-107M CN-106F T

U

V

ZX215-1005036

W

X

Shop Manual - June 2013

Y

Z

7-15

Troubleshooting

SA

NY

LA

TI N

AM E

RI C

A

SY195/205/215/225C9 Crawler Hydraulic Excavator

7-16

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

CN-1-002M 9 CN-1-005 CN-1-001M

A

8

RI C

CN-1-103M

AM E

7

6

5

TI N

CN-1-004M

LA

4

2

SA

3

NY

CN-1-110

CN-150M

1 ZX215-1005037

AA

AB

AC

AD

Shop Manual - June 2013

AE

AF

7-17

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

7.3.2 Electrical element circuit diagram (cab circuit) PF021

CN-1-112 (D-3) 1

CANL

2

22

1

120ȍ resistance

2

CN-616F

CANH CANL 29 22

1 CN-1-111 (D-8)

2 3

24Vpower

4

9

5

1

1

2 3

2 3

0

50 1 5062 00 3

6 7 8

3

3

3

4 8 9 10 12

4 8 9 10 12

4 8 9 10 12

CN-142M (D-12)

50

1

506

2 3

00

9 10

Monitor

Ground

2 3 4

CN-131M CN-302F (D-12) (A-3) 50 50 1 1 1 1 506 506 2 2 2 2 00 3 3 00 3 3 4

5 6

5 6

1

12

CN-412F (A-3) CAN+ B

15

CAN-

16 17

8

0 43

18 19

1

1

2 3

2 3

1

1

2

2

GPS

21 22 23

4 5 9

10

10

11 12

11 12

26 27 28 29 30 31 32 33 34 35 36 38 39 40 41 42 43 44 45 46 47 48

6

F7

10A

28

F9

5A

29

F10

5A

42

F11

43

F14

49

F15

15A

70

F17

10A

20 A

10A

3 4 5 8 9 10 11 12 3 4 5 8 9 10 11 12

AM E

37

5A

26

1 CN-241M (D-12) 1

25

7

15A

F5

2

4 5 9

24

Fuel control knob voltage

F4

25

CN-121F (D-12) 2

CN-204F (A-2)

20

24

20

A

14

5A

RI C

13

20 A

21

11

AIN16

F1 F3

23

CN-7-705 (D-12)

Fuel ctrl dial

CANH

49 50 51 52 54 55 56

00 00 50

TI N

53

s GND s GND s PWR

CAN-

57 58 59

CAN+

60 61 62 64

1

65 66 67 68 69

s GND s PWR s PWR

73 74 75

00 50 50 CAN+ CAN-

76

4

CAN+ CAN-

2

3

3

4

4

5

5

12

71

77 78 79

1

2

LA

70 72

X-1

70

X-2

33 24 25

X-3 X-4 X-5

37

X-6

36

X-7

35 L 72

X-8 X-9

35 H

X-10

23

X-11

CN-132F (D-12)

63

5

28

12

80 81

X-12

CN-615F 83 84 85 86 87 88 89 90 91

SA

3

X-13

NY

82

X-14

23 Top lamp switch

92

20

93

Horn switch

94

95

70

31 21 CN-104M

72

96

97

CN-307M

98

99

TERMINAL B BRACCR1 R2 C HEAT

Work lamp switch

100

OFF ON START

101 102

2

103

24

33

104 CN-303M

105 106

Washer switch

107

22

108

Stabilized voltage diode

109 110

1

25

2

1

42

0

2

114 115

0

0

42

24Vpower supply 24Vpower supply

119 120

9

13

36 25

117

1

11

9

Wiper switch

0

116 118

11

CN-332M S-6

CN-305M

112 113

13

37

CN-153M

CN-152M

111

Ground Ground

Start switch

22 13

35 L 1

42 35 H

42

121

2

3 4 5

2

3 4 5

KB

Battery relay

CN-304M

122

1 1

2

+ -

-

+

Chassis GND

ZX215-1005038

A

7-18

B

C

D

Shop Manual - June 2013

E

F

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

★ This circuit diagram has been compiled by extracting the wiper system and each switch control system from the overall electrical circuit diagram. Access lamp

28 Horn relay

Lamp relay

Top lamp relay

9 K5

K6

K8

1

2

3 4 5

1

2

3 4 5

1

2

1

2

3 4 5

1

2

3 4 5

1

2

31

23

32

33

0

24

72

34

0

3 4 5 70

0

71

8

A

0

3 4 5

CN-1-110 (D-6) 1

1

2 36 3 35H 4

2 3 4

25

X-2

X-3 X-4

1 3 4 5 6 7 8

6 7 8

AM E

X-1 CN-161F (S-16) 1 3 4 5

35 L

X-5 X-6 X-7

TI N

X-10 X-11 X-12 X-13

CN-150M (S-8)

RL+ L0

0 26

1 2 3 4 5

6 7 8

6 7 8

R+ RL+

1 2

1

1 2

F-104 (W-1) CN-661F (S-12)

L0

3 4

71 0

3 4

1

32

0 71

Horn

CN-102M (A-2)

20 b

0

SA

34

38

1

1

2

2

1

1 2

2

1 2

2

CN-107M

Radio panel

1

2

CN-109M

57 61 a 60 a

3

Left boom work lamp

0

Right boom work lamp

0

2

34

Right speaker

1 Left speaker

4

0

5 6

38

0

7

26

38

Rotating stage work lamp

34

CN-102M (A-2) 1

0

34

CN-102M (A-2)

1 2 L+ 3 0 4 20 b 5 R6 L7

57

4

1

1

26

R+

0

5

0 71

F-103 (W-1)

34

20 b

Compressor clutch

M

37

1

F8

21

1 2

2

F6 21

0

1 2

Left top lamp

NY

71

1 2 3 4 5

6

Right top lamp

LA

X-14

7

CN-112M Washer motor (A-2) 1 2

X-9

M

5

5

X-8

R+

Wiper

RI C 0

8

CN-207F

Air conditioner panel

60a 61a

1

2

2

CN-7-111 (S-8)

CN-442F (S-12)

Cab lamp

0 1

4

4

7

7

8

8

8

8

26

1

60a 61a Ex air sensor

ZX215-1005039

G

H

I

J

Shop Manual - June 2013

K

L

7-19

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

7.3.3 Electrical control circuit diagram (engine circuit) CN-616F

6

5

4

Body ground

0

-

+ -

CN-241F (D-12)

20

+

1

42

22 10

1

2

2

9 21 11

9 11

20

13

F1 20 F2 21

20A22 5A10

CN-332M S-6 22 11 11 9

9

11 8

8

TERMINAL B BR ACCR1 R2 C HEAT OFF ON START

13 11

22 13 16

11

PF021

CN-152M CN-153M 1

0

2

42

1

2

42

0

A

506

X-1

RI C

21

AM E

7

22

T-110

00 00 50

TI N

8

1 Grounding 2 3 4 Controller power supply 5 6 7 8 9 10 11 12 13 14 Throttle position feedback 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 5Vpower supply 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 5Vpower supply74 5Vpower supply75 76 77 78 79 80 81

T-102

00 50 50

X-2

10 21

X-3

13

X-4

18

X-5

22

X-6

12

X-7

0

X-8

606

X-9

50

X-10 X-11

507

X-12

MT+

LA

9

T-119

X-13

00

X-14

MT-

CN-221M

F16

1 1

CN-615F

2

1

NY

CN-161F

12 12

27

105

14 14

Pilot switch

SA

3

82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99

100 101 102 103 104 Throttle motor output signal+ 105 106 107 108 109 110 111 112 113 Grounding 114 Grounding 115 116 117 118 24Vpower supply 119 24V power supply120 121 122

MT+

MT0 0

7

7

CN-331F 21

42 42

CN-241F

F11

21

T-102

4 1

2

0

T-101 T-103 T-104

1

2

3 4 5

1

2

3 4 5

1

2

3 4 5

1

2

3 4 5

KB Battery relay

Preheat switch

105 11 12 2

3 4 5

2

3 4 5

18

16 Pilot valve relay

1

K3 1

CN-306M

Locking relay

ZX215-1005040

A

7-20

B

C

D

Shop Manual - June 2013

E

F

G

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

★ This circuit diagram has been compiled by extracting the engine preheat system, startup system and governor system from the overall electrical circuit diagram. T-112

17 Preheat relay

Parking relay

KH

F13 160A T-108

T-109

1

2

3

4

5

1

2

3

4

5

0

18

16

K7

17

CN-661M (S-16)

15 15

1

2

3

4

5

1

2

3

4

5

0

13

9

64 63 65

Preheater

7 7 17 9 9 14 12 12

10

10

Preheater indicator

17

CN-442F (D-12)

1 1

0

X-2

10

CN-121F (D-12) 606

65

12

21

X-4

13

X-5

18

X-6

22

X-7

12

X-8

0

X-9

606 50 507

X-12

MT-

X-13

00

X-14

MT+

7

7

9

9

10

10

64 63

1 2 3 4 6

1 2 3 4 6

0

65

E Parking motor

0

7

CN-613F 12 a 14 10 47 0

1 2

1 2

3 4 6

3 4 6

12a 14 10 47

S L Safety relay R P

6

0

5 10 14 21 47

LA

X-11

6

P1

TI N

X-10

63

64

1

AM E

X-3

1 6

22

8

22 64 B 63 A 65 P2

CN-801F (H-6)

CN-661F (S-16)

5 5

A

21

RI C

X-1

2 2

R L B P

E 0

Generator Body ground

4

NY

CN-112M 1

2

12 a

CN-111F

12

1 1 2 2

12 12 a 21

E

SA

0

Starting motor

3

A3 Body ground

F-310

Charging indicator

10

1 1

14

2 2

F-311

Connector 282080-1 1

CN-316F (AMP-2)

2

0

1

1

2

2

606

2 Pilot solenoid valve

M13 (S-6) 50 507 MT00 MT+

1 2 3 5 6

1 2 3

1 2 Throttle motor 3 5 AC-2000 6

1

5 6

ZX215-1005041

G

H

I

J

Shop Manual - June 2013

K

L

M

7-21

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

7.3.4 Electrical control circuit diagram (sensor and solenoid valve circuit)

1 2 3 4 Controller power supply 5 6 7 8 9 10 Oil level sensor 11 12 13 14 15 16 17 18 Speed sensor GND 19 20 21 22 23 24 25 26 27 28 29 Coolant temp. sensor 30 Hydraulic oil temp. sensor 31 32 33 34 35 36 37 38 Pulse input 39 40 41 42 43 44 45 46 47 Oil pressure switch 48 Travel sensor (left) 49 Bucket dump sensor 50 Boom lower sensor 51 Arm out sensor 52 Rear pump main pressure sensor 53 s GND 54 s GND 55 s PWR 56 57 58 59 60 61 62 63 64 65 66 Travel sensor (right) 67 Swing sensor 68 Bucket curl sensor 69 Boom raise sensor 70 Arm in sensor 71 Front pump main pressure sensor 72 5V power supply GND 73 5Vpower supply GND 74 5Vpower supply GND 75 76 77 78 79 80 81

5

4

0 511

2

1

Engine speed sensor

1

1

2

2

Hydraulic oil temp. sensor

1

1

2

2

240欧 w1/4 F-108 (W-1)

Coolant temp. sensor

A

508 0

RI C

CN-121M (DF-3) A

50 0 201

B C CN-120M (DF-3) A A B B C C

A

B

C

A

Swing pilot pressure sensor

A

B

B

C

C

Bucket curl pilot pressure sensor

CN-127M (DF-3)

50 0 204

A

A

B

B

C

C

Bucket dump pilot pressure sensor

CN-125M (DF-3) A

A

B

B

C

C

Boom lower pilot pressure sensor

CN-126M (DF-3)

50 0 206

A

A

B

B

C

C

Boom raise pilot pressure sensor

CN-128M (DF-3)

50 0 203

A

A

B

B

C

C

Arm in pilot pressure sensor

CN-122M (DF-3)

50 0 202

A

A

B

B

C

C

Arm out pressure sensor

CN-115M (DF-3)

50 0 501

A

A

B

B

C

C

Front pump pressure sensor

CN-116M (DF-3)

50 0 502

NY

A

B

C

CN-124M (DF-3)

50 0 205

A

608 0

1

1

2

2

604 0

1

1

2

2

602 0

1

1

2

2

A

B

B

C

C

Rear pump pressure sensor

CN-133F (AMP-2)

Swing priority-A4 proportional solenoid valve

CN-134F (AMP-2)

Bucket confluent-A5 proportional solenoid valve

CN-132F (AMP-2)

Boom priority 1-A4 proportional solenoid valve

CN-135F (AMP-2)

603 0

1

1

2

2

Boom priority 2-A4 proportional solenoid valve

CN-113F (AMP-2)

702 0

607 0

Left travel pilot pressure sensor

CN-123M (DF-3)

50 0 207

24Vpower supply

Right travel pilot pressure sensor

B C

50 0 208

703 0

Oil pressure switch

A

50 0 200

SA

3

2

510

CN-615F Hi/Lo speed travel

82 83 84 85 86 87 Front pump solenoid proportional valve 88 Rear pump solenoid proportional valve 89 90 91 92 93 94 95 96 97 Swing priority solenoid valve 98 Bucket confluent valve 99 Boom priority 1 100 Boom priority 2 101 102 103 104 105 106 107 108 109 110 111 112 113 Grounding 114 Grounding 115 116 117 118 24Vpower supply 119 24Vpower supply 120 121 122

1

2

CN-152M (A-2)

AM E

6

511 42

TI N

7

1

CN-113M (A-2)

LA

8

Fuel level sensor

CN-448M (S-2)

108A 108B

Grounding

9

CN-101M (S-1) 1 1

509

CN-616F

1

1

2

2

Front pump proportional solenoid valve

CN-114F (AMP-2)

1

1

2

2

Rear pump proportional solenoid valve

CN-131F (AMP-2)

1

1

2

2

Hi/Lo speed travel solenoid valve

ZX215-1005042

A

7-22

B

C

D

Shop Manual - June 2013

E

F

G

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

7.3.5 SWP type connector Female (Socket)

RI C

A

Male (Plug)

7123-7414-40 (No.of pin: 1)

AM E

7222-7414-40

7123-1424-40 (No.of pin: 2)

LA

TI N

7222-1424-40

7123-7464-40 (No.of pin: 6)

SA

NY

7222-7464-40

7222-7484-40

7123-7484-40 (No.of pin: 8)

7222-7564-40

7123-7564-40 (No.of pin: 16)

Shop Manual - June 2013

7-23

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

7.3.6 A/AMP type connector

Female (Socket)

282104-1

282080-1 (No.of pin: 2)

AM E

RI C

A

Male (Plug)

282087-1 (No.of pin: 3)

174352-2 (No.of pin: 2)

SA

NY

174354-2

LA

TI N

282105-1

7-24

1473252-1

1473255-1 (No.of pin: 40)

1473244-1

1473247-1 (No.of pin: 81)

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

7.3.7 DT type connector

Shell (Plug)

Shell (Socket) B

B

A

A

A

DT06-2S

A

B

AM E

B

RI C

DT04-2P

C DT06-3S

C

DT04-3P (No.of pin: 3)

6

6

1

2

5

5

2

3

4

4

3

LA

TI N

1

DT06-6S

DT04-6P (No.of pin: 6) 8 5

5

SA

NY

8

A

4

1

4

1

DT04-8P (No.of pin: 8)

DT06-8S

12

7

7

12

1

6

6

1

DT04-12P (No.of pin: 12)

DT06-12S

Shop Manual - June 2013

7-25

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

7.4 Failure Symptoms and Troubleshooting Codes No.

Troubleshooting

Symptom

Code

E mode H mode (Engine)

Action to be taken concerning Service Code, User Code and Failure Code

6

Color of exhaust gas is too dark.(Incomplete combustion)

S-3

7

Engine pickup is poor.

S-4

8

Engine runs rough or is unstable.

9

Engine is short of output, or lacks power

3

4

RI C

2

A

5

Display User Code in monitor panel Display Service Code in electrical system after checking According to displayed failure history Display Failure Code in mechanical system after checking code failure history Engine-related failure Engine does not start up easily. (It always takes some time to start up the engine) Engine misfires.

E-1

AM E

1

E-2 E-4

S-2

S-5 H-2

S-6

H-5 S-7 S-8 S-9 S-10

16 Abnormal noises are heard

S-12 S-13

LA

13 Excessive fuel consumption Engine cooling water is mixed with engine oil, spurts out 14 or decreases 15 Engine oil amount increases. (Water or fuel gets in)

NY

TI N

10 Auto Idle fails. Excessive engine oil consumption, or color of exhaust gas 11 is blue 12 Premature engine oil contamination

S-1

S-11

17 Excessive vibrations are caused Failure related to work equipment, swing and travel

SA

18 Power supply of machine cannot be cut off.

E-3

19 There are abnormal noises from around hydraulic pump

H-4

20 All work equipment, travel and swing do not move

H-3

21 Speeds of all work equipment, travel and swing are slow When Machine Swings and Travels Simultaneously, 22 Travel Speed Lowers Largely Work equipment-related failure

H-1

23 All the equipment do not work

H-13

E-6

24 Cylinder do not work singly

H-9

25 Drift of cylinder is too large

H-10

26 Work equipment time lag is too big

H-11

7-26

Shop Manual - June 2013

S-6

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

No.

Troubleshooting

Symptom

Code

E mode H mode (Engine)

Other work equipment moves, when specific work equipment is relieved 28 Boom-up speed or power is low.

E-7

H-6

29 Arm speed or power is low.

E-8

H-7

30 Bucket speed or power is low.

E-9

H-8

27

H-12

E-10

32 Dual Speed Travel Not Functioning

E-13

H-15

RI C

31 Travel speed or power is low.

A

Travel-related failure

33 Machine tends to swerve while in travel

H-14

34 Machine is difficult to steer, or lacks power

H-16

H-17

36 Track shoe does not move (only on one side)

AM E

35 Travel speed cannot be shifted

H-18

Swing-related failure 37 Machine does not swing

H-19

38 Swing acceleration is poor, or swing speed is slow Upper structure overruns remarkably when stopping 39 swinging 40 Large shock is made when stopping swinging

H-20

H-22

41 Large sound is made when stopping swinging

H-23

42 Hydraulic drift of swing is large

H-24

LA

TI N

H-21

Monitor panel-related failure E-11

44 Monitor displays nothing.

E-12

45 Engine coolant temperature reading is incorrect.

E-14

NY

43 Monitor display is blank.

E-15

47 Arm-in pilot pressure reading is incorrect.

E-17

48 Arm-out pilot pressure reading is incorrect.

E-18

49 Boom-up pilot pressure reading is incorrect.

E-19

50 Boom-down pilot pressure reading is incorrect.

E-20

51 Bucket-close pilot pressure reading is incorrect.

E-21

52 Bucket-open pilot pressure reading is incorrect.

E-22

53 Swing pilot pressure reading is incorrect.

E-23

54 Left travel pilot pressure reading is incorrect.

E-24

55 Right travel pilot pressure reading is incorrect.

E-25

SA

46 Fuel level reading is incorrect.

Other failure 56 Preheating function fails.

E-5

57 Wiper does not work.

E-16 Shop Manual - June 2013

7-27

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

7.5 Troubleshooting with an Event Code

SA

NY

LA

TI N

AM E

RI C

A

Information in troubleshooting table .......................................................................................... 7-29 E111 (controller memory failure (FROM)) .................................................................................. 7-30 E212 (throttle motor current & motor connection abnormal) ..................................................... 7-31 E213 (throttle motor operation suspends) ................................................................................ 7-32 E214 (throttle motor working range abnormal) .......................................................................... 7-33 E015 (power supply voltage abnormal) ..................................................................................... 7-34 E116 (controller internal temperature abnormal) ....................................................................... 7-35 E017 (abnormal output of 5v power supply in sensor) .............................................................. 7-36 E118 (abnormal communication between controller and monitor) ............................................ 7-37 E320 (abnormality in front pump output pressure) .................................................................... 7-38 E321 (abnormality in rear pump output pressure) ..................................................................... 7-39 E322 (abnormality in arm-in pilot pressure)............................................................................... 7-40 E323 (abnormality in arm-out pilot pressure) ............................................................................ 7-41 E324 (abnormality in boom-raise pilot pressure) ...................................................................... 7-42 E325 (abnormality in boom-lower pilot pressure) ...................................................................... 7-43 E326 (abnormality in bucket-curl pilot pressure) ....................................................................... 7-44 E327 (abnormality in bucket-dump pilot pressure) .................................................................... 7-45 E328 (abnormality in swing pilot pressure ................................................................................. 7-46 E329 (abnormality in left travel pilot pressure) ......................................................................... 7-47 E330 (abnormality in right travel pilot pressure) ........................................................................ 7-48 E231 (abnormality in fuel control dial set voltage) ..................................................................... 7-49 E237 (abnormality in hydraulic oil temperature) ........................................................................ 7-50 E541 (abnormality in engine speed) .......................................................................................... 7-51 E450 (abnormality (a) in front pump proportional solenoid coil current) .................................... 7-52 E450 (abnormality (b) in front pump proportional solenoid coil current) .................................... 7-53 E451 (abnormality (a) in rear pump proportional solenoid coil current)..................................... 7-54 E451 (abnormality (B) in rear pump proportional solenoid coil current) .................................... 7-55 E452 (abnormality (A) in swing priority proportional solenoid coil current)................................ 7-56 E452 (abnormality (B) in swing priority proportional solenoid coil current)................................ 7-57 E453 (abnormality (A) in bucket confluence proportional solenoid coil current) ....................... 7-58 E453 (abnormality (B) in bucket confluence proportional solenoid coil current) ....................... 7-59 E455 (abnormality (A) in boom priority 2 proportional solenoid coil current) ............................. 7-60 E455 (abnormality (B) in boom priority 2 proportional solenoid coil current) ............................. 7-61 E460 (abnormality in dual speed travel solenoid valve) ............................................................ 7-62

7-28

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

Information in troubleshooting table User Code

Service Code

Display on monitor



Trouble

Title of failure shown in failure history

A

Failure is described on the monitor display. When failure is detected, the controller has taken action to protect the affected Response from controller system or equipment. Symptom of machine Symptom that is shown on the machine due to action of controller.

Standard value in normal state and remarks on troubleshooting

RI C

Cause 1 2

4

5

Possible causes of trouble (Given numbers are reference numbers, which do not indicate priority)

● Standard value under normal condition can be used to judge possible causes ● Reference for passing the above "Good" or "No Good" judgement ● Open circuit Faulty contact with connector or open circuit in wiring harness

TI N

3

AM E



● Faulty grounding An ungrounded wiring is grounded.

LA

Possible causes and standard value in normal state

Failure description

● Short circuit A wiring has mistaken contact with a 24 V electric circuit.

NY

Related circuit diagram

SA

This is part of the circuit diagram which shows the portion where the failure occurred. ● Connector No.: A connector number Indicates a connector. ● Arrow: An arrow roughly indicates the installing location.

Shop Manual - June 2013

7-29

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E111 (controller memory failure (FROM)) User Code

Service Code

Trouble Controller memory fails and the system slows down. E111 When the power is on, abnormality is detected by checking through FROM sumFailure description mation and RAM verification. Response from controller Stop the operation of motor and solenoid coil. 11

A

Engine acceleration fails and the machine acts slowly. .

RI C

1

Cause Standard value in normal state/Remarks on troubleshooting Internal failure No troubleshooting can be done for failure occurs in the inner of controller. (If of controller this failure occurs, replace the controller.)

AM E

2 3 4

TI N

5

SA

NY

LA

Possible causes and standard value in normal state

Symptom of machine

7-30

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E212 (throttle motor current & motor connection abnormal) User Code

Service Code

12

Trouble

Throttle motor loading circuit is abnormal and the engine acceleration fails.

E212 When the power is on, magnitude of throttle motor coil current is out of the Failure description range of 0.1A~1.8A and lasts for 2 seconds. Response from controller The controller stops the motor driving system when this failure is detected. Engine acceleration fails and the machine acts slowly.

A

Symptom of machine

4

Internal failure of controller

LA

3

Short circuit of harness (grounded)

RI C

Open circuit of harness

● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-445M ③ and ⑥ Resistance 12.2 Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Unplug the controller and measure the resistance Resistance 12.2 Ω between pin 113 and pin 105. ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Unplug the connector CN-445M and measure the Resistance ≥2M Ω resistance between motor ③ ( ⑥ ) and the housing. No troubleshooting can be done for failure occurs in the inner of controller. (Except for the above reasons, the controller must be replaced in case of failure.)

AM E

2

Failure of throttle motor coil

TI N

1

Standard value in normal state/Remarks on troubleshooting

5

NY

Possible causes and standard value in normal state

Cause

CONTROLLER

75

THRTL FEEDBACK VOLT.

55

MT-

113

SA

SENSOR 5V

GND WIRE MT+

THROTTLE MOTOR

CN-445M 50# 507# MT-

55

0#

105

MT+

GREEN

1

1

2

2

3

3

4

4

5

5

YELLOW

6

6

BLUE

WHITE RED

M

CHASSIS HARNESS

CAB

ZX215-1005071

Shop Manual - June 2013

7-31

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E213 (throttle motor operation suspends) User Code

Service Code

13

Trouble

Operation of throttle motor suspends and engine acceleration fails.

E213 The controller monitoring accuracy deviates by over 5%, which is normally Failure description between 0.8 - 4.2 Voltage, after the system is powered on for 30 seconds. Response from controller The controller stops the motor driving system when this failure is detected. Engine acceleration fails and the machine acts slowly.

A

Symptom of machine

3

4

5

RI C

NY

6

AM E

2

TI N

1

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perFailure of throttle form troubleshooting. motor coil Resistance 12.2 Ω Between CN-445M ③ and ⑥ ● Turn engine start switch to OFF position. Then, keep it at ON position to Failure of 5V perform troubleshooting. power supply Between CN-445M ① and ⑤ Voltage About 5V ● Turn engine start switch to OFF position. Keep it at OFF position to perOpen circuit of form troubleshooting. Unplug the controller and measure the resistance harness Resistance 12.2 Ω between pin 113 and pin 105. ● Turn engine start switch to OFF position. Then, keep it at ON position to Failure of throttle perform troubleshooting. position sensor Between CN-445M ② and ground Voltage 0.8V~3.5V ● Turn engine start switch to OFF position. Keep it at OFF position to perShort circuit form troubleshooting. of harness Unplug the connector CN-445M and measure the Resistance ≥2M Ω (grounded) resistance between motor ③ ( ⑥ ) and the housing. No troubleshooting can be done for failure occurs in the inner of controller. Internal failure of (Except for the above reasons, the controller must be replaced in case of controller failure.)

LA

Possible causes and standard value in normal state

Cause

SA

CONTROLLER SENSOR 5V

50# 75

THRTL FEEDBACK VOLT.

55

MT-

113

GND WIRE MT+

THROTTLE MOTOR

CN-445M 507# MT-

55

0#

105

MT+

GREEN

1

1

2

2

3

3

4

4

5

5

YELLOW

6

6

BLUE

WHITE RED

M

CHASSIS HARNESS

CAB

ZX215-1005071

7-32

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E214 (throttle motor working range abnormal) User Code

Service Code

14

Trouble

Throttle motor working range is abnormal and the engine returns to auto idle.

E214 The voltage is below 0.8V at the minimal stroke or above 4.2V at the maximal Failure description stroke, and it lasts for 100msec when the power is on. Response from controller Turn the throttle to idle speed. Engine returns to auto idle.

A

Symptom of machine

3

4

5

RI C

SA

NY

6

AM E

2

TI N

1

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perFailure of throtform troubleshooting. tle motor coil Resistance 12.2 Ω Between CN-445M ③ and ⑥ ● Turn engine start switch to OFF position. Then, keep it at ON position to Failure of 5V perform troubleshooting. power supply Between CN-445M ① and ⑤ Voltage About 5V ● Turn engine start switch to OFF position. Keep it at OFF position to perOpen circuit of form troubleshooting. Unplug the controller and measure the resistance harness Resistance 12.2 Ω between pin 113 and pin 105. ● Turn engine start switch to OFF position. Then, keep it at ON position to Failure of perform troubleshooting. throttle position Between CN-445M ② and ground Voltage 0.8V—3.5V sensor ● Turn engine start switch to OFF position. Keep it at OFF position to perShort circuit form troubleshooting. Unplug the connector CN-445M and measure the of harness ≥2M Ω resistance between motor ③ ( ⑥ ) and the hous- Resistance (grounded) ing. No troubleshooting can be done for failure occurs in the inner of controller. Internal failure (Except for the above reasons, the controller must be replaced in case of of controller failure.)

LA

Possible causes and standard value in normal state

Cause

CONTROLLER SENSOR 5V

75

THRTL FEEDBACK VOLT.

55

MT-

113

GND WIRE MT+

THROTTLE MOTOR

CN-445M 50# 507# MT-

55

0#

105

MT+

GREEN

1

1

2

2

3

3

4

4

5

5

YELLOW

6

6

BLUE

WHITE RED

M

CHASSIS HARNESS

CAB

ZX215-1005071

Shop Manual - June 2013

7-33

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E015 (power supply voltage abnormal) User Code

Service Code

15

E015

Failure description

Trouble Power supply voltage is abnormal.

Voltage of power supply is above 36V when the machine is running.

Response from controller The system stops the motor and solenoid valve automatically. Symptom of machine

Engine acceleration fails and the machine acts slowly.

AM E

RI C

A

Possible causes and standard value in normal state

Cause Standard value in normal state/Remarks on troubleshooting Failure of ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. 1 power supVoltage ≤25V Measure battery voltage ply ● Turn engine start switch to OFF position. And Then, keep the engine running Alternator to perform troubleshooting. 2 Measure the voltage between the alternator terminal abnormal Voltage About 28V B and ground. 3

CN-613 1 2 3 4 5 6

LA

START SWITCH TERMINAL B BR ACC R1 R2 C

TI N

4

HEAT OFF ON

CN-800M

1

-

+

L

S

R P

E

F-107

2

SA

NY

START

SAFETY RELAY

G R

-

L

P

B

E

ALTERNATOR

+ BATTERY RELAY

0

0 CHASSIS HARNESS

CAB

ZX215-1005072

7-34

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E116 (controller internal temperature abnormal) User Code

Service Code

16

Trouble

Internal temperature of controller is abnormal. Engine acceleration fails and the machine acts slowly.

E116 Internal temperature of controller keeps above 80°C or below -30°C for 10 secFailure description onds when the power is on. Response from controller The controller stops the motor and the solenoid coil.

A

Engine acceleration fails and the machine acts slowly.

RI C

Cause Standard value in normal state/Remarks on troubleshooting Internal No troubleshooting can be done for failure occurs in the inner of controller. (If this 1 failure of failure occurs, replace the controller.) controller

AM E

2 3

TI N

4 5

SA

NY

LA

Possible causes and standard value in normal state

Symptom of machine

Shop Manual - June 2013

7-35

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E017 (abnormal output of 5v power supply in sensor) User Code

Service Code

Trouble Abnormal output of power supply in sensor E017 The controller detects out over current or short circuit of sensor power source Failure description output when the power is on. Response from controller Only output alarm is enabled. 17

A



2

AM E

1

Standard value in normal state/Remarks on troubleshooting Short circuit ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. in harness Measure the resistance between pin 56, pin 75, pin 74 of Resistance ≥2M Ω (grounded) controller KC-MB and the ground. Internal No troubleshooting can be done for failure occurs in the inner of controller. (Except failure of for the above reasons, the controller must be replaced in case of failure.) controller

RI C

Cause

3

TI N

4 5

SA

NY

LA

Possible causes and standard value in normal state

Symptom of machine

7-36

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E118 (abnormal communication between controller and monitor) User Code

Service Code

18

Abnormal communication between controller and monitor

Trouble

E118 Communication of monitor is interrupted for 5 consecutive times when the Failure description power is on. Response from controller Only output alarm is enabled.

A



3

AM E

2

TI N

1

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perFailure of CAN form troubleshooting. resistance Resistance 60 Ω Between CN-7-709 ① and ② ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of Unplug the controller and measure the resistance ≤1 Ω between pin 60 and CN-7-705 ③ harness Resistance Unplug the controller and measure the resistance ≤1 Ω between pin 78 and CN-7-705 ④ No troubleshooting can be done for failure occurs in the inner of controller. Internal failure (Except for the above reasons, the controller must be replaced in case of of controller failure.)

RI C

Cause

4

LA

Possible causes and standard value in normal state

Symptom of machine

CANH

120ȍ RESISTANCE

2 2

NY

CANH CANL

SA

60 78

CN-1-111 CN-441 3 3

1 2 3

1 2 3

29 22 0

CN-7-705 3 3 4 4 8 8 9 9 10 10 12 12

1 1

22

29

3 4 8 9 10 12

F1

MONITOR

CANL

1 1

CANL

CONTROLLER

CANH

CN-7-709

20A

F10 5A 21 PWR

CAB

20 PWR

CHASSIS HARNESS

ZX215-1005073

Shop Manual - June 2013

7-37

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E320 (abnormality in front pump output pressure) User Code

Service Code

20

Trouble

Front pump output pressure is abnormal. Only output alarm is enabled. .

E320 A pressure feedback voltage other than 0.25~4.75V keeps more than 200msec Failure description when the power is on. Response from controller Only output alarm is enabled.

A



3

4

Voltage

About 5V

● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of ≤1 Ω signal wire Between CN-115M C and pin 72 of controller Resistance Between CN-115M B and ground ≤1 Ω Short circuit ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. of signal wire Between CN-115M C and ground Resistance ≥2M Ω (grounded) ● Turn engine start switch to OFF position. Then, keep it at ON position to Failure of senperform troubleshooting. sor Between CN-115M C and ground Voltage 0.5±0.2V

AM E

2

Failure of 5V power supply Between CN-115M A and B

TI N

1

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting.

RI C

Cause

5

LA

Possible causes and standard value in normal state

Symptom of machine

NY

CONTROLLER

SA

FRONT PUMP PRESSUSRE SIGNAL COLLECTING PORT

72

GND WIRE

54

5V PWR SUPPLY

56

CN-446M 501# 00# 50#

FRONT PUMP PRESS. SENSOR

C

SIGNAL

B

GND WIRE

A

5V

CHASSIS HARNESS

CAB

ZX215-1005074

7-38

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E321 (abnormality in rear pump output pressure) User Code

Service Code

21

Trouble

Reading of rear pump output pressure is abnormal. Only output alarm is enabled. .

E321 A pressure feedback voltage other than 0.25~4.75V keeps more than 200msec Failure description when the power is on. Response from controller Only output alarm is enabled.

A



● 2

3

4

Open circuit of signal wire Short circuit ● of signal wire (grounded) ● Failure of sensor

5

RI C



AM E

1

Failure of 5V power supply

Standard value in normal state/Remarks on troubleshooting Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-116M A and B Voltage About 5V Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-116M C and pin 53 of controller ≤1 Ω Resistance Between CN-116M B and ground ≤1 Ω Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-116M C and ground Resistance ≥2M Ω Turn engine start switch to OFF position. Then, keep it at OFF position to perform troubleshooting. Between CN-116M C and ground Voltage 0.5±0.2V

TI N

Cause

LA

Possible causes and standard value in normal state

Symptom of machine

CN-447M

NY

CONTROLLER REAR PUMP PRESSURE SIGNAL COLLECT PORT

53

54

5V PWR SUPPLY

56

SA GND WIRE

502# 00# 50#

REAR PUMP PRESS. SENSOR

C

SIGNAL

B

GND WIRE

A

5V

CHASSIS HARNESS

CAB

ZX215-1005075

Shop Manual - June 2013

7-39

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E322 (abnormality in arm-in pilot pressure) User Code

Service Code

22

Trouble

Arm-in pilot pressure is abnormal. Only output alarm is enabled. .

E322 A pressure feedback voltage other than 0.25~4.75V keeps more than 200msec Failure description when the power is on. Response from controller Only output alarm is enabled.

A

The arm in motion is slow.

● 2

3

4

Open circuit of signal wire Short circuit ● of signal wire (grounded) ● Failure of sensor

RI C



AM E

1

Failure of 5V power supply

Standard value in normal state/Remarks on troubleshooting Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-128M A and B Voltage About 5V Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-128M C and pin 71 of controller ≤1 Ω Resistance Between CN-128M B and ground ≤1 Ω Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-128M C and ground Resistance ≥2M Ω Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-128M C and ground Voltage 0.5±0.2V

TI N

Cause

5

LA

Possible causes and standard value in normal state

Symptom of machine

CONTROLLER

NY

CN-428M

ARM-IN PILOT PRESSURE SIGNAL COLLECTING PORT

71

54

5V PWR SUPPLY

56

SA

GND WIRE

203# 00# 50#

ARM-IN PILOT PRESS. SENSOR

C

SIGNAL

B

GND WIRE

5V

A

CHASSIS HARNESS

CAB

ZX215-1005076

7-40

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E323 (abnormality in arm-out pilot pressure) User Code

Service Code

23

Trouble

Reading of arm-out pilot pressure is abnormal. Only output alarm is enabled.

E323 A pressure feedback voltage other than 0.25 – 4.75V keeps more than Failure description 200msec when the power is on. Response from controller Only output alarm is enabled.

A

Arm-out motion is slow.

2

Failure of 5V power supply Open circuit of signal wire

RI C

1

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-122M A and B Voltage About 5V ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-122M C and pin 52 of controller ≤1 Ω Resistance Between CN-122M B and ground ≤1 Ω

AM E

Cause

TI N

Short circuit ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. 3 of signal wire Between CN-122M C and ground Resistance ≥2M Ω (grounded) ● Turn engine start switch to OFF position. Then, keep it at ON position to Failure of senperform troubleshooting. 4 sor Between CN-122M C and ground Voltage 0.5±0.2V 5

LA

Possible causes and standard value in normal state

Symptom of machine

NY

CONTROLLER ARM-OUT PILOT PRESSURE SIGNAL COLLECTING PORT

52

54

5V PWR SUPPLY

56

SA GND WIRE

CN-122M 202# 00# 50#

ARM-OUT PILOT PRESS. SENSOR

C

SIGNAL

B

GND WIRE 5V

A

CHASSIS HARNESS

CAB

ZX215-1005077

Shop Manual - June 2013

7-41

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E324 (abnormality in boom-raise pilot pressure) User Code

Service Code

24

Trouble

Reading of boom-raise pilot pressure is abnormal. Only output alarm is enabled. .

E324 A pressure feedback voltage other than 0.25 – 4.75V keeps more than Failure description 200msec when the power is on. Response from controller Only output alarm is enabled.

A

Boom-raise motion is slow.

● 2

3

4

Open circuit of signal wire Short circuit ● of signal wire (grounded) ● Failure of sensor

RI C



AM E

1

Failure of 5V power supply

Standard value in normal state/Remarks on troubleshooting Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-126M A and B Voltage About 5V Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-126M C and 70 pin of controller ≤1 Ω Resistance Between CN-126M B and ground ≤1 Ω Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-126M C and ground Resistance ≥2M Ω Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-126M C and ground Voltage 0.5±0.2V

TI N

Cause

5

LA

Possible causes and standard value in normal state

Symptom of machine

CONTROLLER

NY

CN-126M

BOOM-RAISE PILOT PRESS. SIGNAL COLLECTING PORT

SA

GND WIRE

70

5V PWR SUPPLY

206# 00#

54 56

50#

BOOM-RAISE PILOT PRESS. SENSOR

C

SIGNAL

B

GND WIRE 5V

A

CAB

CHASSIS HARNESS

ZX215-1005078

7-42

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E325 (abnormality in boom-lower pilot pressure) User Code

Service Code

25

Trouble

Reading of boom-lower pilot pressure is abnormal. Only output alarm is enabled. .

E325 A pressure feedback voltage other than 0.25 – 4.75V keeps more than Failure description 200msec when the power is on. Response from controller Only output alarm is enabled.

A

Boom-lower motion is slow.

2

3

4

Open circuit of signal wire Short circuit ● of signal wire (grounded) ● Failure of sensor

5

RI C



AM E

1



Failure of 5V power supply

Standard value in normal state/Remarks on troubleshooting Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-125M A and B Voltage About 5V Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-125M C and pin 51 of controller ≤1 Ω Resistance Between CN-125M B and ground ≤1 Ω Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-125M C and ground Resistance ≥2M Ω Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-125M C and ground Voltage 0.5±0.2V

TI N

Cause

LA

Possible causes and standard value in normal state

Symptom of machine

CONTROLLER

NY

CN-125M

BOOM-LOWER PILOT PRESS SIGNAL COLLECTING PORT

SA

GND WIRE

5V PWR SUPPLY

51

207# 00#

54 56

50#

BOOM-LOWER PILOT PRESSURE SENSOR

C

SIGNAL

B

GND WIRE 5V

A

CAB

CHASSIS HARNESS

ZX215-1005079

Shop Manual - June 2013

7-43

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E326 (abnormality in bucket-curl pilot pressure) User Code

Service Code

26

Trouble

Reading of bucket-curl pilot pressure is abnormal. Only output alarm is enabled. .

E326 A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200msec Failure description when the power is on. Response from controller Only output alarm is enabled.

A

Bucket-curl motion is low.

● 2

Open circuit of signal wire

Short circuit ● 3 of signal wire (grounded) ● Failure of sen4 sor

RI C



AM E

1

Failure of 5V power supply

Standard value in normal state/Remarks on troubleshooting Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-124M A and B Voltage About 5V Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-124M C and 69 pin of controller ≤1 Ω Resistance Between CN-124M B and ground ≤1 Ω Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-124M C and ground Resistance ≥2M Ω Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-124M C and ground Voltage 0.5±0.2V

TI N

Cause

5

LA

Possible causes and standard value in normal state

Symptom of machine

CONTROLLER

NY

CN-124M 69

GND WIRE

54

SA

BUCKET-DIG PILOT PRESS. SIGNAL COLLECTING PORT

5V PWR SUPPLY

56

205# 00# 50#

BUCKET-DIG PILOT PRESSURE SENSOR

C

SIGNAL

B

GND WIRE 5V

A

CAB

CHASSIS HARNESS

ZX215-1005080

7-44

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E327 (abnormality in bucket-dump pilot pressure) User Code

Service Code

27

Trouble

Reading of Bucket-dump pilot pressure is abnormal. Only output alarm is enabled. .

E327 A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200msec Failure description when the power is on. Response from controller Only output alarm is enabled.

A

Bucket-dump motion is low

2

Open circuit of signal wire

Short circuit ● 3 of signal wire (grounded) ● Failure of sen4 sor 5

RI C



AM E

1



Failure of 5V power supply

Standard value in normal state/Remarks on troubleshooting Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-128M A and B Voltage About 5V Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-128M C and pin 50 of controller ≤1 Ω Resistance Between CN-128M B and ground ≤1 Ω Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-128M C and ground Resistance ≥2M Ω Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-128M C and ground Voltage 0.5±0.2V

TI N

Cause

LA

Possible causes and standard value in normal state

Symptom of machine

CONTROLLER

NY

CN-128M 50

GND WIRE

54

5V PWR SUPPLY

56

SA

BUCKET-DUMP PILOT PRESS. SIGNAL COLLECTING PORT

204# 00# 50#

BUCKET-DUMP PILOT PRESSURE SENSOR

C

SIGNAL

B

GND WIRE 5V

A

CHASSIS HARNESS

CAB

ZX215-1005081

Shop Manual - June 2013

7-45

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E328 (abnormality in swing pilot pressure User Code

Service Code

28

Trouble

Reading of swing pilot pressure is abnormal. Only output alarm is enabled. .

E328 A pressure feedback voltage other than 0.25 – 4.75V keeps more than Failure description 200msec when the power is on. Response from controller Only output alarm is enabled.

A

Swinging motion is slow.

● 2

Open circuit of signal wire

Short circuit ● 3 of signal wire (grounded) ● Failure of sen4 sor

RI C



AM E

1

Failure of 5V power supply

Standard value in normal state/Remarks on troubleshooting Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-123M A and B Voltage About 5V Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-123M C and pin 68 of controller ≤1 Ω Resistance Between CN-123M B and ground ≤1 Ω Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-123M C and ground Resistance ≥2M Ω Turn engine start switch to OFF position. Then, keep it at OFF position to perform troubleshooting. Between CN-123M C and ground Voltage 0.5±0.2V

TI N

Cause

5

LA

Possible causes and standard value in normal state

Symptom of machine

CONTROLLER

NY

CN-123M

SWING PILOT PRESSURE SIGNAL COLLECTING PORT

SA

GND WIRE

68

5V PWR SUPPLY

208# 00#

54 56

50#

SWING PILOT PRESS. SENSOR

C

SIGNAL

B

GND WIRE 5V

A

CAB

CHASSIS HARNESS

ZX215-1005082

7-46

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E329 (abnormality in left travel pilot pressure) User Code

Service Code

29

Trouble

Reading of left travel pilot pressure is abnormal. Only output alarm is enabled. .

E329 A pressure feedback voltage other than 0.25 – 4.75V keeps more than Failure description 200msec when the power is on. Response from controller Only output alarm is enabled.

A

Left travel speed is low. Travel deviates.

● 2

Open circuit of signal wire

Short circuit ● 3 of signal wire (grounded) ● Failure of sen4 sor 5

RI C



AM E

1

Failure of 5V power supply

Standard value in normal state/Remarks on troubleshooting Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-120M A and B Voltage About 5V Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-120M C and pin 49 of controller ≤1 Ω Resistance Between CN-120M B and ground ≤1 Ω Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-120M C and ground Resistance ≥2M Ω Turn engine start switch to OFF position. Then, keep it at OFF position to perform troubleshooting. Between CN-120M C and ground Voltage 0.5±0.2V

TI N

Cause

LA

Possible causes and standard value in normal state

Symptom of machine

NY

CONTROLLER

SA

L. TRAVEL PILOT PRESSURE SIGNAL COLLECTING PORT

49

GND WIRE

54

5V PWR SUPPLY

56

CAB

CN-120M 200# 00# 50#

L. TRAVEL PILOT PRESS. SENSOR

C

SIGNAL

B

GND WIRE

5V

A

CHASSIS HARNESS

ZX215-1005083

Shop Manual - June 2013

7-47

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E330 (abnormality in right travel pilot pressure) User Code

Service Code

30

Trouble

Reading of right travel pilot pressure is abnormal. Only output alarm is enabled. .

E330 A pressure feedback voltage other than 0.25 – 4.75V keeps more than Failure description 200msec when the power is on. Response from controller Only output alarm is enabled.

A

Right travel speed is low. Travel deviates.

● 2

Open circuit of signal wire

Short circuit ● 3 of signal wire (grounded) ● Failure of sen4 sor

RI C



AM E

1

Failure of 5V power supply

Standard value in normal state/Remarks on troubleshooting Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-121M A and B Voltage About 5V Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-121M C and pin 67 of controller ≤1 Ω Resistance Between CN-121M B and ground ≤1 Ω Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-121M C and ground Resistance ≥2M Ω Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-121M C and ground Voltage 0.5±0.2V

TI N

Cause

5

LA

Possible causes and standard value in normal state

Symptom of machine

CONTROLLER

NY

CN-121M 67

R. TRAVEL PILOT PRESSURE SIGNAL COLLECTING PORT

SA

GND WIRE

5V PWR SUPPLY

201# 00#

54 56

50#

R. TRAVEL PILOT PRESS. SENSOR

C

SIGNAL

B

GND WIRE

A

5V

CHASSIS HARNESS

CAB

ZX215-1005084

7-48

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E231 (abnormality in fuel control dial set voltage) User Code

Service Code

31

Trouble

Voltage setting of fuel control dial is abnormal. Engine returns to auto idle.

E231 The voltage of fuel control dial other than 0.25 – 4.75V keeps more than Failure description 200msec when the power is on. Response from controller The throttle is switched to idle position.

A

Engine returns to auto idle speed.

3

4

Short circuit ● of signal wire (grounded) Short circuit ● of signal wire (contact with Between CN-302F ② and ground Voltage ≤5V power supply) ● Turn engine start switch to OFF position. Keep it at OFF position to perDefective form troubleshooting. Unplug the connector CN-302F, and measure the knob Resistance 5K±15% Ω resistance between dial ① and ③

LA

5



Open circuit of signal wire

AM E

2

TI N

1



Failure of 5V power supply

Standard value in normal state/Remarks on troubleshooting Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-302F ① and ③ Voltage About 5V Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-302F ② and pin 34 of controller Resistance ≤1 Ω Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-302F ② and ground Resistance ≥2M Ω Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting.

RI C

Cause

NY

Possible causes and standard value in normal state

Symptom of machine

SA

SENSOR 5V

75

GND WIRE

55

FUEL CONTROL DIAL SET VOLTAGE

34

CN-142M

CN-131M

1

1

2

2

3

3

CN-302F 50# 506# 0#

1

1

2

2

3

3

YELLOW BLUE

FUEL CTRL DIAL

RED

CAB

ZX215-1005085

Shop Manual - June 2013

7-49

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E237 (abnormality in hydraulic oil temperature) User Code

Service Code

Hydraulic oil temperature is abnormal. Only output alarm is enabled.

E237 A voltage other than 0.2 – 4.75V, transformed from hydraulic oil temperature Failure description that is detected by controller, keeps more than 200msec. Only output alarm is enabled. The alarm resets automatically when conditions Response from controller become normal. Symptom of machine —

2

Open circuit of wire harness

3

Short circuit of wire harness (grounded)

4

Failure of 24V power supply

RI C

Failure of sensor

AM E

1

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Then, keep it at OFF position to perform troubleshooting. Between CN-113M ① and ground Voltage 0.2~4.75V ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-113M ① and pin 31 of controller Resistance ≤1 Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-113M ① and ground Resistance ≥1M Ω ● Turn engine start switch to OFF position. Keep it at ON position to perform troubleshooting. Between CN-113M ② and ground Voltage About 24V

TI N

Cause

5

LA

Possible causes and standard value in normal state

A

37

Trouble

CN-152M 0#

NY

1

1 240Ÿ

CONTROLLER

SA

2

2

CN-113M

HYDRAULIC OIL TEMP SENSOR

31

HYDRAULIC OIL TEMP SENSOR

1

1

SIGNAL

2

2

24V PWR SUPPLY

24VPWR SUPPLY

CHASSIS HARNESS

CAB

ZX215-1005086

7-50

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E541 (abnormality in engine speed) User Code

Service Code

41

E541

Trouble

Engine speed is abnormal. Only output alarm is enabled.

A

CPU detects out that engine speed is too low (below 100 rpm). Only output alarm is enabled. The alarm resets automatically when conditions Response from controller become normal. Symptom of machine —

2

Open circuit of wire harness

3

Short circuit of wire harness (grounded)

4

Failure of sensor

5

RI C

Normal condition

AM E

1

Standard value in normal state/Remarks on troubleshooting ● Code 41 will be displayed on the monitor when engine start switch is turned from the OFF position to the ON position. This is normal as the engine is not started. ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-448M ① and pin 38 of controller ≤1 Ω Resistance Between CN-448M ② and pin 19 of controller ≤1 Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-448M ① and ground Resistance ≥1M Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Unplug the connector CN-448M, and measure the Resistance 2.3±0.2k Ω resistance between the speed sensors's ① and ② .

TI N

Cause

LA

Possible causes and standard value in normal state

Failure description

NY

CONTROLLER

SA

ENGINE SPEED PROBING

GND WIRE

CN-448M 38

19

108A

108B

CAB

ENGINE SPEED SENSOR

1

SIGNAL

2

GND WIRE

CHASSIS HARNESS

ZX215-1005087

Shop Manual - June 2013

7-51

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E450 (abnormality (a) in front pump proportional solenoid coil current) User Code

Service Code

50

Trouble

Front pump proportional solenoid coil current is abnormal. The system operates slowly.

E450 Abnormality occurs in loaded circuit of proportional solenoid coil. Current above Failure description 1.8A lasts for 1 second. Differential current occurs in drive protection loop. Response from controller Stop the solenoid coil when failure is detected. Power supply must be restored.

2

Short circuit of wire harness (grounded)

Failure of pro3 portional valve coil 4

Failure of controller

RI C

Open circuit of wire harness

AM E

1

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-113F ① and pin 88 of controller ≤1 Ω Resistance Between CN-113F ② and ground ≤1 Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-113F ① and wire 0# Resistance ≥1M Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Unplug the connector CN-113F, and measure the Resistance 17.5 Ω resistance between solenoid valve's ① and ② No troubleshooting can be done for failure occurs in the inner of controller. (Except for the above reasons, the controller must be replaced in case of this failure.)

TI N

Cause

A

System operates slowly.

5

LA

Possible causes and standard value in normal state

Symptom of machine

NY

CONTROLLER

88

GND WIRE

55

SA

FRONT PUMP SOLENOID VALVE SIGNAL OUTPUT PORT

CN-113F 702#

0#

1

2

SOLENOID VALVE (FRONT PUMP)

SIGNAL

GND WIRE

CHASSIS HARNESS

CAB

ZX215-1005088

7-52

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E450 (abnormality (b) in front pump proportional solenoid coil current) User Code

Service Code

50

Trouble

Front pump proportional solenoid coil current is abnormal. The system operates slowly.

E450 Abnormality occurs in loaded circuit of proportional solenoid coil. Current above Failure description 0.1 A lasts for 1 second. Differential current occurs in drive protection loop. Response from controller Stop the solenoid coil when failure is detected. Power supply must be restored.

A

System operates slowly.

3

4

AM E

2

TI N

1

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of Between CN-113F ① and pin 88 of controller ≤1 Ω wire harness Resistance Between CN-113F ② and ground ≤1 Ω Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. wire harness Between CN-113F ① and wire 0# Resistance ≥1M Ω (grounded) Failure of pro- ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. portional valve Unplug the connector CN-113F, and measure the Resistance 17.5 Ω coil resistance between solenoid valve's ① and ② . No troubleshooting can be done for failure occurs in the inner of controller. Failure of con(Except for the above reasons, the controller must be replaced in case of this troller failure.)

RI C

Cause

LA

5

NY

Possible causes and standard value in normal state

Symptom of machine

CONTROLLER

CN-113F 88

GND WIRE

55

SA

FRONT PUMP SOLENOID VALVE SIGNAL OUTPUT PORT

702#

0#

1

2

SOLENOID VALVE (FRONT PUMP)

SIGNAL

GND WIRE

CHASSIS HARNESS

CAB

ZX215-1005088

Shop Manual - June 2013

7-53

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E451 (abnormality (a) in rear pump proportional solenoid coil current) User Code

Service Code

51

Trouble

Rear pump proportional solenoid coil current is abnormal. The system operates slowly.

E451 Abnormality occurs in loaded circuit of proportional solenoid coil. Current above Failure description 1.8 A lasts for 1 second. Differential current occurs in drive protection loop. Response from controller Stop the solenoid coil when failure is detected. Power supply must be restored.

A

System operates slowly.

3

4

AM E

2

TI N

1

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of Between CN-114F ① and pin 89 of controller ≤1 Ω wire harness Resistance Between CN-114F ② and ground ≤1 Ω Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. wire harness Between CN-114F ① and wire 0# Resistance ≥1M Ω (grounded) ● Turn engine start switch to OFF position. Keep it at OFF position to perFailure of proform troubleshooting. portional valve Unplug the connector CN-114F, and measure the Resistance 17.5 Ω coil resistance between solenoid valve's ① and ② . No troubleshooting can be done for failure occurs in the inner of controller. Failure of con(Except for the above reasons, the controller must be replaced in case of this troller failure.)

RI C

Cause

5

LA

Possible causes and standard value in normal state

Symptom of machine

NY

CONTROLLER

SA

REAR PUMP SOLENOID VALVE SIGNAL OUTPUT PORT 

GND WIRE

702#

89

55

CAB

CN-114F

0#

1

2

SOLENOID VALVE (REAR PUMP) SIGNAL

GND WIRE

CHASSIS HARNESS

ZX215-1005089

7-54

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E451 (abnormality (B) in rear pump proportional solenoid coil current) User Code

Service Code

51

Trouble

Rear pump proportional solenoid coil current is abnormal. The system operates slowly.

E451 Abnormality occurs in loaded circuit of proportional solenoid coil. Current above Failure description 0.1 A lasts for 1 second. Differential current occurs in drive protection loop. Response from controller Stop the solenoid coil when failure is detected. Power supply must be restored.

A

System operates slowly.

3

4

AM E

2

TI N

1

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of Between CN-114F ① and pin 89 of controller ≤1 Ω wire harness Resistance Between CN-114F ② and ground ≤1 Ω Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. wire harness Between CN-114F ① and wire 0# Resistance ≥1M Ω (grounded) ● Turn engine start switch to OFF position. Keep it at OFF position to perFailure of proform troubleshooting. portional valve Unplug the connector CN-114F, and measure the Resistance 17.5 Ω coil resistance between solenoid valve's ① and ② No troubleshooting can be done for failure occurs in the inner of controller. Failure of con(Except for the above reasons, the controller must be replaced in case of this troller failure.)

RI C

Cause

5

LA

Possible causes and standard value in normal state

Symptom of machine

NY

CONTROLLER

SA

REAR PUMP SOLENOID VALVE SIGNAL OUTPUT PORT 

GND WIRE

CN-114F 702# 89

55

CAB

0#

1

2

SOLENOID VALVE (REAR PUMP) SIGNAL

GND WIRE

CHASSIS HARNESS

ZX215-1005089

Shop Manual - June 2013

7-55

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E452 (abnormality (A) in swing priority proportional solenoid coil current) User Code

Service Code

Current through the proportional solenoid coil for swing priority is abnormal.

E452 Abnormality occurs in loaded circuit of proportional solenoid coil. Current above Failure description 1.8A lasts for 1 second. Differential current occurs in drive protection loop. Operation of solenoid coil is stopped when failure is detected. Power supply Response from controller must be restored. Symptom of machine —

3

4

RI C

TI N

2

LA

1

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of Between CN-133F ① and pin 98 of controller ≤1 Ω wire harness Resistance Between CN-133F ② and ground ≤1 Ω Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. wire harness Between CN-133F ① and wire 0# Resistance ≥1M Ω (grounded) ● Turn engine start switch to OFF position. Keep it at OFF position to perFailure of proform troubleshooting. portional valve Unplug the connector CN-133F, and measure the Resistance 17.5 Ω coil resistance between solenoid valve's ① and ② No troubleshooting can be done for failure occurs in the inner of controller. Failure of con(Except for the above reasons, the controller must be replaced in case of this troller failure.)

AM E

Cause

5

NY

Possible causes and standard value in normal state

A

52

Trouble

SA

CONTROLLER

98

GND WIRE

55

SWING PRIORITY SOLENOID VALVE SIGNAL OUTPUT PORT 

CN-133F 608#

0#

CAB

SOLENOID VALVE (SWING PRIORITY)

1

SIGNAL

2

GND WIRE

CHASSIS HARNESS

ZX215-1005090

7-56

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E452 (abnormality (B) in swing priority proportional solenoid coil current) User Code

Service Code

Current through the proportional solenoid coil for swing priority is abnormal.

E452 Abnormality occurs in loaded circuit of proportional solenoid coil. Current above Failure description 0.1A lasts for 1 second. Differential current occurs in drive protection loop. Operation of solenoid coil is stopped when failure is detected. Power supply Response from controller must be restored. Symptom of machine —

3

4

RI C

TI N

2

LA

1

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of Between CN-133F ① and pin 98 of controller ≤1 Ω wire harness Resistance Between CN-133F ② and ground ≤1 Ω Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. wire harness Resistance ≥1M Ω Between CN-133F ① and wire 0# (grounded) ● Turn engine start switch to OFF position. Keep it at OFF position to perFailure of proform troubleshooting. portional valve Unplug the connector CN-133F, and measure the Resistance 17.5 Ω coil resistance between solenoid valve's ① and ② No troubleshooting can be done for failure occurs in the inner of controller. Failure of con(Except for the above reasons, the controller must be replaced in case of this troller failure.)

AM E

Cause

5

NY

Possible causes and standard value in normal state

A

52

Trouble

CONTROLLER

SA

SWING PRIORITY SOLENOID VALVE SIGNAL OUTPUT PORT 

GND WIRE

CN-133F 98

55

608#

0#

CAB

SOLENOID VALVE (SWING PRIORITY)

1

SIGNAL

2

GND WIRE

CHASSIS HARNESS

ZX215-1005090

Shop Manual - June 2013

7-57

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E453 (abnormality (A) in bucket confluence proportional solenoid coil current) User Code

Service Code

Current through the proportional solenoid coil for bucket confluence is abnormal. Motion of bucket is slow.

E453 Abnormality occurs in loaded circuit of proportional solenoid coil. Current above Failure description 1.8 A lasts for 1 second. Differential current occurs in drive protection loop. Operation of solenoid coil is stopped when failure is detected. Power supply Response from controller must be restored. Symptom of machine Motion of bucket is slow.

3

4

RI C

TI N

2

LA

1

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of Between CN-134F ① and 99 pin of controller ≤1 Ω wire harness Resistance Between CN-134F ② and ground ≤1 Ω Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. wire harness Between CN-134F ① and wire 0# Resistance ≥1M Ω (grounded) ● Turn engine start switch to OFF position. Keep it at OFF position to perFailure of proform troubleshooting. portional valve Unplug the connector CN-134F, and measure the Resistance 17.5 Ω coil resistance between solenoid valve's ① and ② No troubleshooting can be done for failure occurs in the inner of controller. Failure of con(Except for the above reasons, the controller must be replaced in case of this troller failure.)

AM E

Cause

5

NY

Possible causes and standard value in normal state

A

53

Trouble

SA

CONTROLLER

BUCKET CONFLUENCE SOLENOID VALVE SIGNAL OUTPUT PORT 

GND WIRE

99

55

CN-134F 604#

0#

CAB

SOLENOID VALVE (BUCKET CONFLU)

1

SIGNAL

2

GND WIRE

CHASSIS HARNESS

ZX215-1005091

7-58

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E453 (abnormality (B) in bucket confluence proportional solenoid coil current) User Code

Service Code

Current through the proportional solenoid coil for bucket confluence is abnormal. Motion of bucket is slow.

E453 Abnormality occurs in loaded circuit of proportional solenoid coil. Current above Failure description 0.1A lasts for 1 second. Differential current occurs in drive protection loop. Operation of solenoid coil is stopped when failure is detected. Power supply Response from controller must be restored. Symptom of machine Motion of bucket is slow.

3

4

RI C

TI N

2

LA

1

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of Between CN-134F ① and pin 99 of controller ≤1 Ω wire harness Resistance Between CN-134F ② and ground ≤1 Ω Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. wire harness Between CN-134F ① and wire 0# Resistance ≥1M Ω (grounded) ● Turn engine start switch to OFF position. Keep it at OFF position to perFailure of proform troubleshooting. portional valve Unplug the connector CN-134F, and measure the Resistance 17.5 Ω coil resistance between solenoid valve's ① and ② No troubleshooting can be done for failure occurs in the inner of controller. Failure of con(Except for the above reasons, the controller must be replaced in case of this troller failure.)

AM E

Cause

5

NY

Possible causes and standard value in normal state

A

53

Trouble

SA

CONTROLLER

BUCKET CONFLUENCE SOLENOID VALVE SIGNAL OUTPUT PORT 

GND WIRE

CN-134F 99

55

604#

0#

CAB

SOLENOID VALVE (BUCKET CONFLU)

1

SIGNAL

2

GND WIRE

CHASSIS HARNESS

ZX215-1005091

Shop Manual - June 2013

7-59

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E455 (abnormality (A) in boom priority 2 proportional solenoid coil current) User Code

Service Code

Current through the proportional solenoid coil for boom priority is abnormal.

E455 Abnormality occurs in loaded circuit of proportional solenoid coil. Current above Failure description 1.8 A lasts for 1 second. Differential current occurs in drive protection loop. Operation of solenoid coil is stopped when failure is detected. Power supply Response from controller must be restored. Symptom of machine —

3

4

RI C

TI N

2

LA

1

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of Between CN-135F ① and pin 101 of controller ≤1 Ω wire harness Resistance Between CN-135F ② and ground ≤1 Ω Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. wire harness Between CN-135F ① and wire 0# Resistance ≥1M Ω (grounded) ● Turn engine start switch to OFF position. Keep it at OFF position to perFailure of proform troubleshooting. portional valve Unplug the connector CN-135F, and measure the Resistance 17.5 Ω coil resistance between solenoid valve's ① and ② No troubleshooting can be done for failure occurs in the inner of controller. Failure of con(Except for the above reasons, the controller must be replaced in case of this troller failure.)

AM E

Cause

5

NY

Possible causes and standard value in normal state

A

55

Trouble

CONTROLLER

SA

BOOM PRIORITY 2 SOLENOID VALVE SIGNAL OUTPUT PORT 

GND WIRE

101

55

CN-135F 603#

0#

CAB

SOLENOID VALVE (BOOM PRIORITY 2 )

1

SIGNAL

2

GND WIRE

CHASSIS HARNESS

ZX215-1005093

7-60

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E455 (abnormality (B) in boom priority 2 proportional solenoid coil current) User Code

Service Code

Current through the proportional solenoid coil for boom priority is abnormal.

E455 Abnormality occurs in loaded circuit of proportional solenoid coil. Current above Failure description 0.1A lasts for 1 second. Differential current occurs in drive protection loop. Operation of solenoid coil is stopped when failure is detected. Power supply Response from controller must be restored. Symptom of machine —

3

4

RI C

TI N

2

LA

1

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of Between CN-135F ① and pin 101 of controller ≤1 Ω wire harness Resistance Between CN-135F ② and ground ≤1 Ω Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. wire harness Between CN-135F ① and wire 0# Resistance ≥1M Ω (grounded) ● Turn engine start switch to OFF position. Keep it at OFF position to perFailure of proform troubleshooting. portional valve Unplug the connector CN-135F, and measure the Resistance 17.5 Ω coil resistance between solenoid valve's ① and ② No troubleshooting can be done for failure occurs in the inner of controller. Failure of con(Except for the above reasons, the controller must be replaced in case of this troller failure.)

AM E

Cause

5

NY

Possible causes and standard value in normal state

A

55

Trouble

CONTROLLER

SA

BOOM PRIORITY 2 SOLENOID VALVE SIGNAL OUTPUT PORT 

GND WIRE

CN-135F

101

55

603#

0#

CAB

SOLENOID VALVE (BOOM PRIORITY 2 )

1

SIGNAL

2

GND WIRE

CHASSIS HARNESS

ZX215-1005093

Shop Manual - June 2013

7-61

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E460 (abnormality in dual speed travel solenoid valve) User Code

Service Code

60

E460

Failure description

Trouble

Connection of the solenoid coil for dual speed travel is abnormal. High speed travel is not functioning.

Abnormality, open circuit or short circuit occurs in the proportional solenoid coil.

Response from controller Only output alarm is enabled. High speed travel is not functioning.

3

4

RI C

AM E

2

TI N

1

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of Between CN-132F ① and pin 100 of controller ≤1 Ω wire harness Resistance Between CN-132F ② and ground ≤1 Ω Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. wire harness Between CN-132F ① and wire 0# Resistance ≥1M Ω (grounded) ● Turn engine start switch to OFF position. Keep it at OFF position to perFailure of proform troubleshooting. portional valve Unplug the connector CN-132F, and measure the Resistance 17.5 Ω coil resistance between solenoid valve's ① and ② No troubleshooting can be done for failure occurs in the inner of controller. Failure of con(Except for the above reasons, the controller must be replaced in case of this troller failure.)

A

Cause

5

LA

Possible causes and standard value in normal state

Symptom of machine

NY

CONTROLLER

SA

DUAL SPEED TRAVEL SOLENOID VALVE SIGNAL OUTPUT PORT 

GND WIRE

100

55

CN-132F 607#

0#

CAB

SOLENOID VALVE (DUAL-SPEED TRAVEL)

1

SIGNAL

2

GND WIRE

CHASSIS HARNESS

ZX215-1005094

7-62

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

7.6 Troubleshooting of Electrical System (E - Mode)

SA

NY

LA

TI N

AM E

RI C

A

Information in troubleshooting table .......................................................................................... 7-64 E-1 Engine does not start ......................................................................................................... 7-65 E-2 Engine runs rough or is unstable ....................................................................................... 7-67 E-3 Power supply of machine cannot be cut off ....................................................................... 7-68 E-4 Auto idle not functioning ..................................................................................................... 7-70 E-5 Preheating function fails..................................................................................................... 7-71 E-6 Work equipment does not work ......................................................................................... 7-72 E-7 Boom-raise speed or power is low ...................................................................................... 7-73 E-8 Arm speed or power is low ................................................................................................. 7-74 E-9 Bucket speed or power is low ............................................................................................ 7-75 E-10 Travel speed or power is low ........................................................................................... 7-77 E-11 Blank monitor display ....................................................................................................... 7-78 E-12 Monitor displays nothing .................................................................................................. 7-79 E-13 Dual speed travel not functioning..................................................................................... 7-80 E-14 Incorrect engine coolant reading...................................................................................... 7-81 E-15 Incorrect fuel level reading ................................................................................................ 7-82 E-16 Wiper does not work ........................................................................................................ 7-83 E-17 Incorrect arm-in pilot pressure reading ............................................................................ 7-84 E-18 Incorrect arm-out pilot pressure reading .......................................................................... 7-85 E-19 Incorrect boom-raise pilot pressure reading .................................................................... 7-86 E-20 Incorrect boom-lower pilot pressure reading.................................................................... 7-87 E-21 Incorrect bucket-curl pilot pressure reading ..................................................................... 7-88 E-22 Incorrect bucket-dump pilot pressure reading.................................................................. 7-89 E-23 Incorrect swing pilot pressure reading ............................................................................. 7-90 E-24 Incorrect left travel pilot pressure reading ........................................................................ 7-91 E-25 Incorrect right travel pilot pressure reading...................................................................... 7-92

Shop Manual - June 2013

7-63

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

Information in troubleshooting table ● The following information is contained in the troubleshooting table and related electric circuit diagrams. Fully understand these information before carrying out troubleshooting. Trouble

Trouble which occurs on the machine

Related information

Information related to detected trouble or troubleshooting

RI C

A

Standard value in normal state and remarks on troubleshooting

1 2

4

● Standard value in normal state, which is used to judge possible causes that might be OK or N/G. ● A reference value is used to determine OK or N/G.

LA

5

< Description >

TI N

Possible causes of trouble (Given numbers are reference numbers, which do not indicate priority)

AM E

3

NY

Possible causes and standard value in normal state

Cause

SA

Related circuit diagram

This is part of the circuit diagram which shows the portion where the failure occurred. ● Connector No.: A connector number Indicates a connector. ● Arrow: An arrow roughly indicates the installing location.

7-64

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E-1 Engine does not start Trouble

Engine cannot be started.

Related information

5

RI C

AM E

4

ness

Wire 12# and start relay terminal SW

Resistance

≤1 Ω

NY

Start relay terminal L and safety relay terminal S ≤1 Ω Failure of 6 Battery terminal "+" (wire 20#) and control dial wire 22# Resistance ≤1 Ω fuse F1 Short cir- ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. cuit of wire 7 Start relay terminal SW and ground ≥1 M Ω harness Resistance Engine input terminal S and ground ≥1 M Ω (grounded) Internal ● Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. 8 failure of Alternator terminal P and ground Voltage ≤1V alternator ● Turn engine start switch to OFF position. Move it to START position when performing troubleshooting. 9 Start relay Terminal SW and ground App. 24V Voltage Terminal S and ground App. 24V ● Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Failure of 10 ≤1 Ω parking unit Between CN-801F 2 and 3 Resistance Unplug connector CN-801F; measure resistance of motor coil. App 63 Ω

SA

Possible causes and standard value in normal state

3

TI N

2

LA

1

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform trouLow battery bleshooting. capacity ≥24V Battery voltage Voltage ● Turn engine start switch to OFF position. Keep it at OFF position to perform trouInternal failbleshooting. ure of start Resistance ≥1M Ω OFF position: between wire 22# and wire 11# switch ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Failure of ≤1 Ω pilot switch Lockout lever FREE position: between 105 # and 27# wire Resistance Lockout lever LOCKED position: between wire 105# and 27# ≥1 M Ω ● Turn engine start switch to OFF position. Keep the engine running during troubleshooting. (When all power supplies, grounding, signal and engine inputs are normal except engine output, it is the failure of start motor) Failure of Engine start motor Start switch Voltage start motor Power supply: Terminal B and ground 20~30V Start Between engine input terminal S and ground 20~30V ● Turn engine start switch to OFF position. Then, keep it at OFF position to perform troubleshooting. Open circuit Wire 21# and start motor terminal B ≤1 Ω of wire har-

A

Cause

Shop Manual - June 2013

7-65

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

START SWITCH B

TERMINAL

20

BATTERY

CN-241F (D-12)

20

1 2

21

F1

20A 22

F2

5A

OFF ON

10

START

9 12

RI C

A

BATTERY RELAY 21 1

2

3 4 5

1

2

3 4 5

11

10

2

12

22 13

22

1

9

BR ACC R1 R2 C

HEAT

PILOT SWITCH

105

F16 10A

0

AM E

LOCK RELAY

1

2

3 4 5

1

2

3 4 5

22

TI N

0

PARK RELAY

LA

CN-661F (S-16) 64 10 10 63 9 9 6 6 65

0

1 1

2 2

3 4 5 3 4 5

15 15

1

1

2

2

3

3

6

6

64 22 65 63

A B P1 P2

E 0

12a 14

12

47

21

12a 1 2 14 3 10 4 47

HLR CHARGE INDICATOR

1 2 3 4

SA

NY

13

CN-161F (S-16)

10 10

PARK MOTOR

CN-801F (H-6)

CN-613F (L-6)

10 12a 10 47

S

L

L S R P

B

10 14

SW

R L B P

S

B

ALTERNATOR

E

0

E

START RELAY

0

E

0

START MOTOR

SAFETY RELAY ZX215-1005095

7-66

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

Trouble

Engine Runs Rough or Is Unstable

Related information

Engine speed can be read on the monitor.

2

Internal failure in sensor

Short circuit of 3 wire harness (grounded) Internal failure 4 of controller

A

Open circuit of wire harness

RI C

1

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Unplug the connector controller, and measure Resistance 2.3±0.2 K Ω the resistance between pin 19 and pin 38. ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-448M A and B Resistance 2.3±0.2 K Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-448M B and ground Resistance ≥1M Ω No troubleshooting can be done due to internal failure. (Failure lies in the controller if the reasons above are ruled out)

AM E

Cause

TI N

5

CONTROLLER

NY

SPEED SENSOR INPUT SIGNAL

LA

Possible causes and standard value in normal state

E-2 Engine runs rough or is unstable

SA

GND

CN-448M (S-2)

38

A

19

B

CAB

SPEED SENSOR SIGNAL

GND

CHASSIS HARNESS

ZX215-1005096

Shop Manual - June 2013

7-67

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E-3 Power supply of machine cannot be cut off Trouble Related information

Engine cannot be stopped. Engine stalls when start switch it turned to OFF position. There is no time delay for power cutout.

When engine start switch is operated, if the operation of battery Failure of batrelay contact is heard, the battery is normal. Turn the start switch tery relay OFF→ON→OFF. ● Turn engine start switch to OFF position. Keep it at OFF position to per-

RI C

Breakdown of form troubleshooting. 2 surge diode Between battery relay wire 20# and wire 21#

AM E

3

TI N

4

5

NY SA 7-68

A

1

Standard value in normal state/Remarks on troubleshooting

LA

Possible causes and standard value in normal state

Cause

Shop Manual - June 2013

Resistance ≥1M Ω

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

START SWITCH B

TERMINAL

20

BATTERY

CN-241F (D-12)

20

1 2

21

F1 F2

5A

OFF ON

10

START

9 12

21 2

3 4 5

1

2

3 4 5

RI C

A

BATTERY RELAY

1

11

10

2

12

22 13

22

1

9

BR ACC R1 R2 C

HEAT

20A 22

PILOT SWITCH

105

F16 10A

AM E

0

LOCK RELAY

1

2

3 4 5

1

2

3 4 5

TI N

0

PARK RELAY

CN-661F (S-16) 64 10 10 63 9 9 6 6 65

0 13

CN-161F (S-16) 10 10

1 1

2 2

3 4 5 3 4 5

15 15

1

1

2

2

3

3

6

6

64 22 65 63

A B P1 P2

E 0

12a 14

12

47

21

12a 1 2 14 3 10 4 47

HLR CHARGE INDICATOR

1 2 3 4

SA

PARK MOTOR

CN-801F (H-6)

NY

LA

22

CN-613F (L-6)

10 12a 10 47

S

L

L S R P

B

10 14

SW

R L B P

S

B

ALTERNATOR

E

0

E

START RELAY

0

E

0

START MOTOR

SAFETY RELAY ZX215-1005095

Shop Manual - June 2013

7-69

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E-4 Auto idle not functioning Trouble Related information

Auto idle speed do not work Engine speed do not decrease wen the mode is auto idle speed and grip keeps still in "NEUTRAL" position

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Error of boom1 Levers in NEUTRAL, pressure signal transmitted 0 KG raise signal Pressure Lever in operation, pressure signal transmitted 0~39 KG ● Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Error of boom2 Levers in NEUTRAL, pressure signal transmitted 0 KG lower signal Pressure Lever in operation, pressure signal transmitted 0~39 KG ● Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Error of arm-in 3 0 KG Levers in NEUTRAL, pressure signal transmitted signal Pressure Lever in operation, pressure signal transmitted 0~39 KG ● Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Error of arm-out 4 Levers in NEUTRAL, pressure signal transmitted 0 KG signal Pressure Lever in operation, pressure signal transmitted 0~39 KG ● Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Error of bucket5 Levers in NEUTRAL, pressure signal transmitted 0 KG curl signal Pressure Lever in operation, pressure signal transmitted 0~39 KG ● Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Error of Bucket6 0 KG dump signal Levers in NEUTRAL, pressure signal transmitted Pressure Lever in operation, pressure signal transmitted 0~39 KG ● Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Error of swing 7 Levers in NEUTRAL, pressure signal transmitted 0 KG signal Pressure Lever in operation, pressure signal transmitted 0~39 KG ● Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. 8 Error of travel Levers in NEUTRAL, pressure signal transmitted 0 KG Pressure signal Lever in operation, pressure signal transmitted 0~39 KG ● Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Error of attach9 Levers in NEUTRAL, pressure signal transmitted 0 KG ment signal Pressure Lever in operation, pressure signal transmitted 0~39 KG Failure of con- No troubleshooting can be done for it is internal failure. (If it is not caused by 10 one of the factors listed above, it should be the failure of controller.) troller

7-70

AM E

TI N

LA

NY

SA

Possible causes and standard value in normal state

RI C

A

Cause

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E-5 Preheating function fails Trouble

Engine does not preheat.

Related information Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform Failure of pretroubleshooting. 1 heat fuse Between wire 21# and preheat relay pin 3# (contact) Resistance ≤1 Ω When the preheating function is activated, if operation of the preheat relay Failure of pre2 contact is heard, the relay is normal. The preheat switch is to be switched heat relay OFF→ON→OFF. ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Failure of pre- Turn off the preheat switch and measure the resistance ≥1M Ω 3 heat switch between wire 16# and wire 18#. Resistance Turn on the preheat switch and measure the resistance ≤1 Ω between wire 16# and wire 18# Short circuit ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. of wire har4 ness (groundBetween preheat relay pin 3# (contact) and ground Resistance ≥1M Ω ed)

TI N

AM E

RI C

A

Possible causes and standard value in normal state

Cause

+

_

+

20

1 9

START SWITCH TERMINAL

B

BR ACC R1 R2 C

HEAT OFF ON

CN-241F (D-12) 1 9

NY

_

BATTERY

LA

5

START 22

20 F1 20A 22

13

16

22 16

SA

BATTERY RELAY 1

2 3 45

1

2 3 45

0

21

21

PREHEAT RELAY PREHEAT CN-142M SWITCH CN-131M (D-12) (D-12)

F13 160A

18

1 1

7 7

6 6

2 345 2 345

GR-1 GLOW PLUG

17

PREHEATER CHASSIS HARNESS

CAB

CHASSIS HARNESS

ZX215-1005097

Shop Manual - June 2013

7-71

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E-6 Work equipment does not work Trouble

The machine is motionless while operated after starting.

Possible causes and standard value in normal state

Related information Cause

3

AM E

2

RI C

A

1

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Failure of lockout Item Lockout control lever Resistance switch LOCK ≤1 Ω Between wire 105# and wire 27# FREE ≥1M Ω Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. wire harness ≥1M Ω Between 105# and ground Resistance (grounded) Failure of coil ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. inside lockout Resistance About 34 Ω Between CN-136F 1 and 2 solenoid valve

TI N

4

PILOT SWITCH

CN-106F (AMP-2) F16 10A 21

27

2

2

1

1

27

2

2

105

CN-161F (S-16)

LA

B-

10 10

SA

NY

12 12

0 1 1

105 2 2

27 606 3 45 3 45

CN-661F CN-136F (S-16) (AMP-2) 1

1

1

1

8

8

2

2

PILOT SOLENOID VALVE

CAB

CHASSIS HARNESS

ZX215-1005098

7-72

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E-7 Boom-raise speed or power is low Trouble

Boom-raise speed or power is low. Pilot pressure of the boom in operation can be checked on the monitor.

Failure of sensor

2

Short circuit of harness (grounded)

3

Open circuit of harness

4

Failure of controller

AM E

RI C

1

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Levers in NEUTRAL, boom-raise pressure signal 0 KG Pressure Lever in operation, boom-raise pressure signal 0~39 KG ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between harness ( from controller pin 70 to CN-126M Resistance ≥1M Ω A) and ground ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. ≤1 Ω Between controller pin 54 and CN-126M B Resistance No troubleshooting can be done due to internal failure. (Failure lies in the controller if the reasons above are ruled out)

A

Cause

CONTROLLER

BOOM UP PRESSURE SENSOR SENSOR GND WIRE

70

SENSOR 5V

TI N

Possible causes and standard value in normal state

Related information

CN-126M (DF-3)

BOOM UP PRESS. SENSOR SIGNAL

54

B

GND WIRE

56

C

NY

LA

A

CAB

5V

CHASSIS HARNESS

SA

ZX215-1005099

Shop Manual - June 2013

7-73

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E-8 Arm speed or power is low Trouble

Arm speed or power is low during operation.

Related information

Pilot pressure of the arm in operation can be checked on the monitor.

3

4

A

RI C

AM E

2

TI N

1

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Failure of sen- Levers in NEUTRAL, arm-in and arm-out pressure 0 KG signals sor Pressure Levers in operation, arm-in and dump pressure 0~39 KG signal ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Short circuit Between harness (from controller pin 71 to CNof harness 128M A) and ground Resistance ≥1M Ω (grounded) Between harness (from controller pin 52 to CN122M A) and ground ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of Between controller pin 54 and CN-128M B harness ≤1 Ω Resistance Between controller pin 54 and CN-122M B Failure of con- No troubleshooting can be done due to internal failure. (Failure lies in the troller controller if the reasons above are ruled out)

NY

LA

Possible causes and standard value in normal state

Cause

CN-122M (DF-3)

ARM-OUT PRESS. SENSOR

A

SIGNAL

B

GND WIRE 5V

C

SA

CONTROLLER

ARM-OUT PRESS SENSOR

52

CN-128M (DF-3)

ARM-IN PRESS SENSOR

71

A

SIGNAL

SENSOR GND WIRE

54

B

GND WIRE

SENOSR 5V

56

C

CAB

ARM-IN PRESS. SENSOR

5V

CHASSIS HARNESS

ZX215-1005119

7-74

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E-9 Bucket speed or power is low Trouble

Bucket speed or power is low during operation.

Related information

Pilot pressure of the bucket can be checked on the monitor.

4

confluence About 17.5 Between CN-134F 1 and 2 Resistance solenoid Ω valve Failure of No troubleshooting can be done due to internal failure. (Failure lies in the controlcontroller ler if the reasons above are ruled out)

SA

NY

5

TI N

AM E

RI C

A

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Failure of 1 Levers in NEUTRAL, bucket-curl/dump pressure signals 0 KG sensor Pressure Levers in operation, bucket-curl/dump pressure signals 0~39 KG ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Short circuit Between harness (from controller pin 69 to CN-124M A) 2 of harness and ground (grounded) Between harness (from controller pin 50 to CN-127M A) Resistance ≥1M Ω and ground ● Turn engine start switch to OFF position. Keep it at OFF position to perform Open circuit troubleshooting. 3 Between controller pin 54 and CN-124M B of harness ≤1 Ω Resistance Between controller pin 54 and CN-127M B Defective ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. bucket

LA

Possible causes and standard value in normal state

Cause

Shop Manual - June 2013

7-75

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

CN-127M (DF-3)

BUCKET-DUMP PRESS. SENSOR

A

SIGNAL

B

GND WIRE

C

5V

50

CN-124M (DF-3)

BUCKET-DUMP PRESS. SENSOR

69

A

SENSOR GND WIRE

54

B

SENOSR 5V

56

C

BUCKET CONFLUENCE SIGNAL

99

SIGNAL GND WIRE

AM E

5V

BUCKET CONFLUENCE PROPORTIONAL VALVE

1

SIGNAL

2

GND WIRE

LA

TI N

CN-134F (AMP-2)

CAB

BUCKET-CURL PRESS. SENSOR

RI C

BUCKET-CURL PRESS. SENSOR

A

CONTROLLER

CHASSIS HARNESS

SA

NY

ZX215-1005100

7-76

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

Trouble

Travel speed or power is low during operation.

Related information

Pilot pressure of travel operation can be checked on the monitor.

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Failure of sen- Levers in NEUTRAL, left and right travel pressure 0 KG 1 signals sor Pressure Levers in operation, left and right travel pressure 0~39 KG signals ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Short circuit Between harness (from controller pin 49 to CN2 of harness 120M A) and ground Resistance ≥1M Ω (grounded) Between harness (from controller pin 67 to CN-

AM E

RI C

A

Cause

TI N

121M A) and ground ● Turn engine start switch to OFF position. Keep it at OFF position to perform Open circuit of troubleshooting. 3 Between controller pin 54 and CN-120M B Beharness ≤1 Ω Resistance tween controller pin 54 and CN-121M B Failure of con- No troubleshooting can be done due to internal failure. (Failure lies in the con4 troller troller if the reasons above are ruled out)

NY

LA

Possible causes and standard value in normal state

E-10 Travel speed or power is low

CN-121M (DF-3)

RIGHT TRAVEL PRESS. SENSOR

A

SIGNAL

B

GND WIRE

C

5V

CONTROLLER

LEFT TRAVEL PRESS. SENSOR

67

CN-120M (DF-3)

49

A

SIGNAL

SENSOR GND WIRE

54

B

GND WIRE

SENOSR 5V

56

C

SA

RIGHT TRAVEL PRESS SENSOR LEFT TRAVEL PRESS SENSOR

5V

CHASSIS HARNESS

CAB

ZX215-1005101

Shop Manual - June 2013

7-77

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E-11 Blank monitor display Trouble

Monitor display is blank after the machine is powered on.

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. 1 Failure of fuse Between wire 22# and ground About 24V Voltage About 24V Between wire 29# and ground ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of Between CN-7-705 pin 8 and CN-241F pin 3 ≤1 Ω 2 wire harness Between CN-7-705 pin 9 and CN-241 pin 1 Resistance ≤1 Ω

RI C

A

Cause

AM E

Between CN-7-705 pin 10# and ground ≤1 Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Short circuit of Between harness (from CN-7-705 pin 8 to CN-241 ≥1M Ω 3 wire harness pin 3) and ground Resistance (grounded) Between harness (from CN-7-705 pin 9 to CN-241 ≥1M Ω pin 1) and ground Failure of No troubleshooting can be done for it is internal failure. (If it is not caused by 4 monitor one of the factors listed above, it should be the failure of monitor.) CN-1-112 (D-3)

LA

CANH

TI N

Possible causes and standard value in normal state

Related information

CANL

CN-1-111 (D-6) 1 1 2 2 3 3

60 78

SA

CANL

120ȍ RESISTANCE

2 2

3 3 1 1 CN-241F (D-12)

CANH CANL 29 22 0

CN-7-705 (D-12) 3 3 4 4 8 8 9 9 10 10 12 12

22

29

3 4 8 9 10 12 F1

20A

F10

5A

MONITOR

CANH

NY

CONTROLLER

1 1

20

21 PWR

CAB

PWR

CHASSIS HARNESS ZX215-1005102

7-78

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E-12 Monitor displays nothing Display of monitor is illuminated but no information is shown on the screen after machine is powered on.

Trouble

3

4

Between CN-1-112 1 and 2

Resistance

120 Ω

RI C

2

Failure of resistance

● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of Between CN-7-705 pin 3 and controller pin 60 ≤1 Ω wire harness Resistance Between CN-7-705 pin 4 and controller pin 78 ≤1 Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Short circuit of Between harness (from CN-7-705 pin 3 to con≥1M Ω wire harness troller pin 60) and ground Resistance (grounded) Between harness (from CN-7-705 pin 4 to control≥1M Ω ler pin 78) and ground Failure of monitor No troubleshooting can be done for it is internal failure. (If it is not one of or controller the failures stated above, it should be the failure of monitor or controller.)

AM E

1

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting.

A

Cause

TI N

Possible causes and standard value in normal state

Related information

LA

CANH

CN-1-112 (D-3)

CANL

60

CANL

78

SA

CANH

120ȍ RESISTANCE

2 2

CN-1-111 (D-6) 1 1 2 2 3 3

3 3 1 1 CN-241F (D-12)

CANH CANL 29 22 0

CN-7-705 (D-12) 3 3 4 4 8 8 9 9 10 10 12 12

22

29

3 4 8 9 10 12 F1

20A

F10

5A

MONITOR

NY

CONTROLLER

1 1

20

21 PWR

CAB

PWR

CHASSIS HARNESS ZX215-1005102

Shop Manual - June 2013

7-79

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

Trouble

Only low speed travel is functioning during operation.

Related information

Press the Hi/Lo button on the monitor to change travel speed.

AM E

RI C

A

Cause Standard value in normal state/Remarks on troubleshooting Failure of dual ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. 1 speed travel Between CN-131F A and B Resistance About 17.5 Ω solenoid valve ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of 2 Between CN-132F pin A and controller pin 100 ≤1 Ω wire harness Resistance Between CN-132F pin B and controller pin 55 ≤1 Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perform Short circuit of troubleshooting. 3 wire harness Between harness (from CN-132F pin A to conResistance ≥1M Ω (grounded) troller pin (100) and ground 4

CONTROLLER

GROUND

100

55

LA

HIGH SPEED TRAVEL SOLENOID VALVE

TI N

Possible causes and standard value in normal state

E-13 Dual speed travel not functioning

A

SIGNAL

B

GND WIRE

ZX215-1005104

SA 7-80

HIGH SPEED TRAVEL SOLENOID VALVE

CHASSIS HARNESS

NY

CAB

CN-132F (AMP-2)

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E-14 Incorrect engine coolant reading Engine coolant temperature sensor cannot correctly reflect current coolant temperature. Coolant temperature can be checked on the monitor.

Trouble Related information

Standard value in normal state/Remarks on troubleshooting Standard values for engine coolant temperature sensor 60°C

Failure of coolant temperature sensor

56.3 Ω

RI C

1

80 Ω

A

50°C 80°C

29.5 Ω

100°C

16.5 Ω

106°C

14.3 Ω

3

4

10 Ω

● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting.

Resistance Between wire 510# and controller pin 30 ≤1 Ω ● Turn engine start switch to OFF position. Keep it at OFF position to Short circuit of perform troubleshooting. lead (grounded) Between wire 510# and ground Resistance ≥1M Ω ● Turn engine start switch to OFF position. Keep it at OFF position to Lead short to 24V perform troubleshooting. circuit Voltage ≤1V Wire 510# to ground

TI N

2

Open circuit of lead

AM E

120°C

NY

᥻ࠊ఼

LA

Possible causes and standard value in normal state

Cause

SA

‫⏽⎆ैދ‬ᑺӴᛳ఼

30

510

偒偊ᅸ

䔺䑿㒓ᴳ

ZX215-1005105

Shop Manual - June 2013

7-81

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

Trouble

Engine fuel level sensor cannot correctly reflect current fuel level.

Related information

Fuel level can be checked on the monitor.

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Fuel level senFuel level Pin Resistance 1 sor error FULL (Upper limit) Approx. 10 Ω Between wire 509# and ground

Open circuit of lead

Short circuit of 3 lead (grounded) 4

Lead short to 24V

EMPTY (Lower limit) 85-95 Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Resistance Between wire 509# and controller pin 11 ≤1 Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Resistance Between wire 509# and ground ≥1M Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Voltage ≤1V Wire 509# grounded

AM E

2

RI C

A

Cause

TI N

Possible causes and standard value in normal state

E-15 Incorrect fuel level reading

LA

CONTROLLER

FUEL LEVEL SENSOR

509

NY

11

CAB

SA

CHASSIS HARNESS

7-82

ZX215-1005106

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E-16 Wiper does not work Trouble

Wiper does not work

RI C

A

Cause Standard value in normal state/Remarks on troubleshooting Internal Fail- ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. 1 ure of wiper Resistance Between wiper wire 25# and ground >10 Ω motor ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of Between CN-241F 1 and CN-1-110 (2) ≤1 Ω 2 lead Between wiper switch wire 35L# and CN-1-110 (5) Resistance ≤1 Ω

AM E

Between wiper switch wire 35L# and CN-1-110 (4) ≤1 Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perform Short circuit of troubleshooting. 3 lead (ground- Harness from CN-241F 1 to CN-1-110 2 short to Resistance ≥1M Ω ed) ground 4

TI N

Possible causes and standard value in normal state

Related information

WIPER SWITCH

CN-132M (D-12)

F15 5A

25

1 21

SA

PWR

1

25

3

3

4

4

36 35L 35H

CN-113F (D-12)

4

CN-1-110 (D-6)

2

2

3

3

4

4

5

5

25 36 35L

M

35H

NY

CN-241M (D-12)

11

1

LA

CN-121F (D-12)

CAB

ZX215-1005107

Shop Manual - June 2013

7-83

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E-17 Incorrect arm-in pilot pressure reading Trouble

Reading of arm-in pilot pressure is incorrect.

3

4

RI C

2

Failure of sensor

AM E

1

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Then, keep it at ON position to Failure of 5V perform troubleshooting. power supply Between CN-128M ① and ③ Voltage Approx. 5V ● Turn engine start switch to OFF position. Keep it at OFF position to perOpen circuit of form troubleshooting. signal wire Between CN-128M ② and controller pin 71 Resistance ≤Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Short circuit of signal wire Resistance ≥2M Ω Between CN-128M ② and ground

A

Cause

● Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. 0.5V~ 4.5V Between CN-128M ② and ground Voltage

5

TI N

Possible causes and standard value in normal state

Related information

LA

CONTROLLER

ARM IN PRESS SENSOR

71

2

SIGNAL

SENSOR GND WIRE

55

3

GND WIRE

SENSOR 5V

75

1

5V

NY

ARM IN PRESS SENSOR

SA 7-84

CN-128M (DF-3)

CAB

CHASSIS HARNESS

ZX215-1005108

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E-18 Incorrect arm-out pilot pressure reading Trouble

Reading of arm-out pilot pressure is incorrect.

3

Short circuit of signal wire

4

Failure of sensor







A

2

Open circuit of signal wire



RI C

1

Failure of 5V power supply

Standard value in normal state/Remarks on troubleshooting Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-122M ① and ③ Voltage About 5V Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-122M ② and controller pin 52 Resistance ≤1 Ω Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Resistance ≥2M Ω Between CN-122M ② and ground Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. 0.5V~ 4.5V Between CN-122M ② and ground Voltage

AM E

Cause

5

TI N

Possible causes and standard value in normal state

Related information

ARM OUT PRESS SENSOR

LA

CONTROLLER

CN-122M (DF-3)

ARM OUT PRESS SENSOR

2

SIGNAL

SENSOR GND WIRE

55

3

GND WIRE

SENSOR 5V

75

1

NY

52

CHASSIS HARNESS

SA

CAB

5V

ZX215-1005109

Shop Manual - June 2013

7-85

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E-19 Incorrect boom-raise pilot pressure reading Trouble

Incorrect Boom-Raise Pilot Pressure Reading

Cause

4

Failure of sensor

A

3

Short circuit of signal wire



RI C

2

Open circuit of signal wire





AM E

1

Failure of 5V power supply

Standard value in normal state/Remarks on troubleshooting Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-126M ① and ③ Voltage About 5V Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-126M ② and controller pin 70 Resistance ≤1 Ω Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Resistance ≥2M Ω Between CN-126M ② and ground Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. 0.5V~ 4.5V Between CN-126M ② and ground Voltage



5

TI N

Possible causes and standard value in normal state

Related information

LA

CONTROLLER

BOOM UP PRESS SENSOR

70

2

SIGNAL

SENSOR GND WIRE

55

3

GND WIRE

SENSOR 5V

75

1

5V

NY

BOOM UP PRESS SENSOR

CHASSIS HARNESS

SA

CAB

7-86

CN-126M (DF-3)

ZX215-1005110

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E-20 Incorrect boom-lower pilot pressure reading Trouble

Boom-Lower pilot pressure reading is incorrect.

3

Short circuit of signal wire

4

Failure of sensor







A

2

Open circuit of signal wire



RI C

1

Failure of 5V power supply

Standard value in normal state/Remarks on troubleshooting Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-125M ① and ③ Voltage About 5V Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-125M ② and controller pin 51 Resistance ≤1 Ω Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Resistance ≥2M Ω Between CN-125M ② and ground Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. 0.5V~ 4.5V Between CN-125M ② and ground Voltage

AM E

Cause

5

TI N

Possible causes and standard value in normal state

Related information

BOOM DOWN PRESS SENSOR

LA

CONTROLLER

SENSOR GND WIRE

BOOM DOWN PRESS SENSOR

51

2

SIGNAL

55

3

GND WIRE

75

1

5V

NY

SENSOR 5V

CN-125M (DF-3)

CAB

SA

CHASSIS HARNESS

ZX215-1005111

Shop Manual - June 2013

7-87

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E-21 Incorrect bucket-curl pilot pressure reading Trouble

Bucket-curl pilot pressure reading is incorrect.

3

Short circuit of signal wire

4

Failure of sensor







A

2

Open circuit of signal wire



RI C

1

Failure of 5V power supply

Standard value in normal state/Remarks on troubleshooting Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-124M ① and ③ Voltage About 5V Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-124M ② and controller pin 69 Resistance ≤1 Ω Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Resistance ≥2M Ω Between CN-124M ② and ground Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. 0.5V~ 4.5V Between CN-124M ② and ground Voltage

AM E

Cause

5

TI N

Possible causes and standard value in normal state

Related information

CONTROLLER

BUCKET CURL PRESS SENSOR

69

2

SIGNAL

SENSOR GND WIRE

55

3

GND WIRE

SENSOR 5V

75

1

5V

NY

LA

BUCKET CURL PRESS SENSOR

CHASSIS HARNESS

SA

CAB

7-88

CN-124M (DF-3)

ZX215-1005112

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E-22 Incorrect bucket-dump pilot pressure reading Trouble

Bucket-dump pilot pressure reading is incorrect.

3

4

RI C

2

AM E

1

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Then, keep it at ON position to Failure of 5V perform troubleshooting. power supply Between CN-127M ① and ③ Voltage About 5V ● Turn engine start switch to OFF position. Keep it at OFF position to perOpen circuit of form troubleshooting. signal wire Between CN-127M ② and controller pin 50 Resistance ≤1 Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perShort circuit of form troubleshooting. signal wire Resistance ≥2M Ω Between CN-127M ② and ground ● Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Failure of sensor 0.5V~ 4.5V Between CN-127M ② and ground Voltage

A

Cause

5

CONTROLLER

50

LA

BUCKET DUMP PRESS SENSOR

TI N

Possible causes and standard value in normal state

Related information

CN-127M (DF-3) 2

SIGNAL GND WIRE

SENSOR GND WIRE

55

3

SENSOR 5V

75

1

NY

BUCKET DUMP PRESS SENSOR

5V

CHASSIS HARNESS

SA

CAB

ZX215-1005113

Shop Manual - June 2013

7-89

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E-23 Incorrect swing pilot pressure reading Trouble

Swing pilot pressure reading is incorrect.

3

4

RI C

2

AM E

1

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Then, keep it at ON position Failure of 5V to perform troubleshooting. power supply Between CN-123M ① and ③ Voltage About 5V ● Turn engine start switch to OFF position. Keep it at OFF position to perOpen circuit of form troubleshooting. signal wire Between CN-123M ② and controller pin 68 Resistance ≤1 Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perShort circuit of form troubleshooting. signal wire Resistance ≥2M Ω Between CN-123M ② and ground ● Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Failure of sensor 0.5V~ 4.5V Between CN-123M ② and ground Voltage

A

Cause

5

TI N

Possible causes and standard value in normal state

Related information

CONTROLLER

SWING PILOT PRESS SENSOR

68

2

SIGNAL

SENSOR GND WIRE

55

3

GND WIRE

SENSOR 5V

75

1

5V

NY

LA

SWING PILOT PRESS SENSOR

CHASSIS HARNESS

SA

CAB

7-90

CN-123M (DF-3)

ZX215-1005114

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E-24 Incorrect left travel pilot pressure reading Trouble

Left Travel Pilot Pressure Reading is incorrect.

3

Short circuit of signal wire





● 4

Failure of sensor

A

2

Open circuit of signal wire



RI C

1

Failure of 5V power supply

Standard value in normal state/Remarks on troubleshooting Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-120M ① and ③ Voltage About 5V Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-120M ② and controller pin 49 Resistance ≤1 Ω Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Resistance ≥2M Ω Between CN-120M ② and ground Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. 0.5V~ 4.5V Between CN-120M ② and ground Voltage

AM E

Cause

5

TI N

Possible causes and standard value in normal state

Related information

CONTROLLER

CN-120M (DF-3)

LEFT TRAVEL PILOT PRESSURE SENSOR

49

2

SENSOR GND WIRE

55

3

GND WIRE

75

1

5V

NY

SENSOR 5V

LA

LEFT TRAVEL PILOT PRESSURE SENSOR

SIGNAL

CHASSIS HARNESS

SA

CAB

ZX215-1005115

Shop Manual - June 2013

7-91

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

E-25 Incorrect right travel pilot pressure reading Trouble

Right travel pilot pressure reading is incorrect.

3

4

RI C

2

AM E

1

Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Then, keep it at ON position to Failure of 5V perform troubleshooting. power supply Between CN-121M ① and ③ Voltage About 5V ● Turn engine start switch to OFF position. Keep it at OFF position to perOpen circuit of form troubleshooting. signal wire Between CN-121M ② and controller pin 67 Resistance ≤1 Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perShort circuit of form troubleshooting. signal wire Resistance ≥2M Ω Between CN-121M ② and ground ● Turn engine start switch to OFF position. Then, keep it at ON position to Failure of senperform troubleshooting. sor 0.5V~ 4.5V Between CN-121M ② and ground Voltage

A

Cause

5

TI N

Possible causes and standard value in normal state

Related information

CN-121M (DF-3)

LA

CONTROLLER

RIGHT TRAVEL PILOT PRESSURE SENSOR

67

2

SIGNAL

SENSOR GND WIRE

55

3

GND WIRE

75

1

NY

SENSOR 5V

5V

CHASSIS HARNESS

SA

CAB

7-92

RIGHT TRAVEL PILOT PRESSURE SENSOR

ZX215-1005116

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

7.7 Troubleshooting of Hydraulic and Mechanical Systems (H - Mode)

SA

NY

LA

TI N

AM E

RI C

A

A Schematic of hydraulic system and mechanical system ........................................................ 7-94 Information contained in troubleshooting table .......................................................................... 7-96 H-1 Work equipment speed slow, or swing and travel speeds slow ......................................... 7-97 H-2 Engine speed drops sharply or engine stalls ..................................................................... 7-98 H-3 Work equipment, swing, and travel systems do not work .................................................. 7-99 H-4 Abnormal noise in hydraulic pump ................................................................................... 7-100 H-5 Auto deceleration not functioning..................................................................................... 7-101 H-6 Boom speed slow ............................................................................................................ 7-102 H-7 Arm speed slow ............................................................................................................... 7-103 H-8 Bucket speed slow ........................................................................................................... 7-104 H-9 Work equipment cylinders no response in separate operation ....................................... 7-105 H-10 Work equipment drifts excessively ................................................................................ 7-106 H-11 Work equipment moves sluggishly ............................................................................... 7-108 H-12 Other work equipment moves while single oil circuit is relieved .................................... 7-108 H-13 Travel speed drops considerably while swinging and travelling .................................... 7-109 H-14 Machine deviates during travel ...................................................................................... 7-110 H-15 Travel speed is low .........................................................................................................7-111 H-16 Machine is not steered well or steering power is low..................................................... 7-112 H-17 Travel speed cannot be changed................................................................................... 7-113 H-18 Travel system fails (only at one side)............................................................................. 7-114 H-19 Swing operation fails...................................................................................................... 7-115 H-20 Swing acceleration poor or swing speed low ................................................................. 7-117 H-21 Upper structure overruns remarkably when it stops swinging ....................................... 7-119 H-22 Large shock is produced when upper structure stops swinging .................................... 7-120 H-23 High noise is produced when upper structure stops swinging ....................................... 7-120 H-24 Swing drift excessive ..................................................................................................... 7-121

Shop Manual - June 2013

7-93

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

A Schematic of hydraulic system and mechanical system

PILOT VALVE - R

A

DUMP

BUCKET CURL

BOOM LOWER

BWD

FWD

FWD

RIGHT

LEFT

BWD

TRAVEL TRAVEL (LEFT) (RIGHT)

SWING

OUT

IN

ARM

PILOT VALVE - TRAVEL

RAISE

PILOT VALVE - L

RI C

LOCK (PILOT VALVE )

16

BOOM PRIORITY

1

2

3

4

5

6

7

8

9

10 11 12

15

BUCKET CONFLUENCE

14

SWING PRIORITY

AM E

ACCUMULATOR

13

VARIABLE SPEED (TRAVEL)

TI N

1 2

19

3

LA

20

18

NY

17

SA

REGULATOR

REGULATOR

SERVO MECHANISM

SERVO MECHANISM

P1

P2

M

FRONT

REAR

ZX225-1105039

7-94

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

● The system schematic is a simplified hydraulic circuit schematic, which can be used as a reference to the hydraulic system and the mechanical system.

12

BOOM CYLINDER

9

S&S

5

Su

BOOM VALVE

S&S

10

BACKUP VALVE

L. TRAVEL VALVE

Su

6

S&S

BACKUP ACTUATOR

9

BOOM 2

3

4

SWING VALVE

SWING MOTOR

1 2

Su

8

SERVO MECHANISM

R. TRAVEL VALVE

Sa

Su

LA

TRAVEL MOTOR (L)

7

Sa

STRT. TRAVEL VALVE

BALANCE VALVE

TI N

SERVO MECHANISM

13

Sa

Sa

13 BALANCE VALVE

S&S

9

ANTISWING ANTISWING VALVE VALVE

S&S

BUCKET CYLINDER

Su

BUCKET VALVE

2

Su

S&S

VALVE S&S ARM S&S REG. VALVE

14

Sa

11

1

2

ARM 2 VALVE

BOOM HOLD VALVE

10

1

15

AM E

ARM HOLD VALVE

BUCKET CYLINDER

BUCKET CONFLUENCE

BACKUP VALVE CONFLUENCE

RI C

1

A

6DSAFETY VALVE 6X SUCTION VALVE 6 6 SAFETY&SUCTION

TRAVEL MOTOR (R)

NY

3

SA

ZX225-1105040

Shop Manual - June 2013

7-95

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

Information contained in troubleshooting table

Trouble which occurs on the machine

Related information

Information related to detected trouble or troubleshooting

A

Trouble

Standard value in normal state/Remarks on troubleshooting

RI C

Cause 1

4

Possible causes of < Description > trouble (Given numbers ● Standard value in normal state, which is used to judge possible are reference numbers, causes that might be OK or N/G. which do not indicate ● A reference value is used to determine OK or N/G. priority)

TI N

3

AM E

2

LA

5

SA

NY

Possible causes and standard value in normal state

● The following information is contained in the troubleshooting table and related electric circuit diagrams. Fully understand these information before carrying out troubleshooting.

7-96

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

H-1 Work equipment speed slow, or swing and travel speeds slow Trouble Related information

2

A

Control levers

Main relief pressure 33~34.3 MPa {337~350 kg/cm²}

Arm in

AM E

valve

RI C

Defective adjustment or malfunction of main relief

● Stop the engine. Perform troubleshooting while the engine is running at high idle.

If normal pressure cannot be restored after adjustment, it is possible the failure of main relief valve or internal defect. Check the valve directly. ● Stop the engine. Perform troubleshooting while the engine is running at high idle. Control levers Pilot control pressure

Malfunction of pilot relief valve

TI N

1

Standard value in normal state/Remarks on troubleshooting

All levers in "NEUTRAL"

3.9~4.1 MPa {40~42 kg/cm²}

3

Malfunction of regulator

4

Malfunction of If the trouble is caused by other factors, it might be the main pump that has main pump performance deterioration, malfunction or internal defect.

LA

The regulator possibly fails. Check the servo mechanism of the regulator.

SA

NY

Possible causes and standard value in normal state

Cause

● Work equipment speed is slow or the travel and swing speeds are slow. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.

Shop Manual - June 2013

7-97

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

H-2 Engine speed drops sharply or engine stalls Trouble

● Engine speed drops sharply or engine stalls. ● Information concerned

Cause

Standard value in normal state/Remarks on troubleshooting

1

Failure of injection pump Injection pump may be defective. Check it directly.

2

Malfunction of regulator

4

A

Clogging of oil filter element Carbon buildup at fuel injection nozzle

RI C

3

Regulator may have malfunction. Check its servo mechanism. Oil filter element may be clogged. Check the element directly. Carbon built up at fuel injection nozzle. Check it directly.

Clogging of air cleaner

Air cleaner may be clogged. Check it directly.

6

Abnormal wear of engine Engine may be worn abnormally. Check it directly.

7

Failure of oil pump

AM E

5

Oil pump may be defective. Check it directly.

SA

NY

LA

TI N

Possible causes and standard value in normal state

Related information

7-98

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

H-3 Work equipment, swing, and travel systems do not work Trouble Related information

A

Malfunction of pilot relief solenoid valve

● Stop the engine. Perform troubleshooting while the engine is running at high idle. Pilot lockout control lever Pilot relief pressure LOCKED

AM E

The main pump may have malfunction or internal defect. Check it by Failure of hydraulic following method. pump ● Remove the oil pressure measurement plug and start the engine. If oil flows out of the opening, the piston pump is in good condition. Internal failure of the coupling can stop rotation of the pump shaft. Check the coupling. Failure of coupling ● Loosen the oil delivery line of the pilot pump. If no oil is seen, it is probably the failure of coupling.

SA

NY

4

● Stop the engine. Perform troubleshooting while the engine is running at high idle. Failure of relief valve Control lever Pilot relief pressure (pilot pump) 3.9~4.1 MPa All levers in "NEUTRAL" {40~42 kg/cm²}

TI N

3

0 {0}

3.9~4.1 MPa {40~42 kg/cm²}

FREE

2

RI C

1

Standard value in normal state/Remarks on troubleshooting

LA

Possible causes and standard value in normal state

Cause

● Whole work equipment, swing, and travel systems do not work. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.

Shop Manual - June 2013

7-99

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

H-4 Abnormal noise in hydraulic pump Trouble

● Abnormal noise is produced from the hydraulic pump ―

Cause

Standard value in normal state/Remarks on troubleshooting

1

Low level of hydraulic oil

2

Inferior hydrauHydraulic oil probably contains air. Make a visual check. lic oil

4

5

It is probably the clogging of hydraulic tank strainer that causes negative pressure in the oil suction line. Make a visual check.

Failure of main The main pump may have internal defect. Check the main pump. pump

LA NY SA 7-100

A

RI C

It is probably the clogging of the vent on top of the hydraulic tank that causes negative pressure in the hydraulic tank. Press the release button of the breather valve to eliminate air. Check again if the noise disappears.

AM E

3

Clogging of vent on top of hydraulic tank Clogging of hydraulic tank strainer

Make a visual check.

TI N

Possible causes and standard value in normal state

Related information

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

H-5 Auto deceleration not functioning Trouble

Cause

A

● Stop the engine. Perform troubleshooting while the engine is running at high idle. Control levers Pilot valve output pressure Malfunction "NEUTRAL" 0 {0} of sensor

RI C

1

Standard value in normal state/Remarks on troubleshooting

3.5~4.1MPa {36~42 kg/cm²}

Operation

Operation Failure of controller

3.5~4.1MPa {36~42 kg/cm²}

TI N

3

AM E

● Stop the engine. Perform troubleshooting while the engine is running at high idle. Control levers Pilot valve output pressure Malfunction 2 "NEUTRAL" 0 {0} of pilot valve

Controller may be defective. Check it directly.

SA

NY

LA

Possible causes and standard value in normal state

Related information

● Auto-deceleration is not functioning. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.

Shop Manual - June 2013

7-101

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

H-6 Boom speed slow Trouble

● The boom moves slowly. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.

Related information

Standard value in normal state/Remarks on troubleshooting

A

"NEUTRAL"

0 {0}

Boom RAISE Boom LOWER

≥3.5MPa {36 kg/cm²}

● Stop the engine. Perform troubleshooting while the engine is running at high idle. Check the pressure sensor by replacing it with a new one.

AM E

Failure of pressure 2 sensor

Malfunction of boom Spool of boom control valve may have malfunction. Check it directly. control valve (spool) Malfunction of boom Retaining valve of boom control valve may have malfunction. Check the 4 control valve (revalve directly. taining valve) Malfunction or defective seal of boom The relief valve and makeup valve in boom control valve may have mal5 control valve function or defective seal. Check the valves directly. (Relief valve and makeup valve) ● Stop the engine. Perform troubleshooting while the engine is running at high idle. Charge the bucket with a load of approximate 1260 kg. Cut off the oil passage to the high-pressure side of the cylinder. Disconnect the cylinFailure of boom der from the main valve. Measure the displacement of piston for 15 min6 cylinder utes after the cylinder becomes stable. If the measured value is greater than 10 mm, it is deemed that cylinder has a defective seal. For more information on the measuring procedure refer to "Testing and Adjusting", "Hydraulic Drift (Work Equipment) - Test".

LA

TI N

3

SA

NY

Possible causes and standard value in normal state

Malfunction of right 1 pilot valve (boom circuit)

● Stop the engine. Perform troubleshooting while the engine is running at high idle. Boom control lever Pilot valve output pressure

RI C

Cause

7-102

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

H-7 Arm speed slow Trouble

● The arm moves slowly. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.

Related information

● Stop the engine. Perform troubleshooting while the engine is running at high idle. Arm control lever Pilot valve output pressure

A

Malfunction of left pilot valve (arm circuit)

"NEUTRAL" Arm IN or Arm OUT

4

LA

5

AM E

3

≥3.5MPa {36 kg/cm²}

TI N

2

0 {0}

● Stop the engine. Perform troubleshooting while the engine is running at high idle. Failure of pressure sensor Check the pressure sensor by replacing it with a new one. Malfunction of arm control Spool of arm control valve may have malfunction. Check it directly. valve (spool) Malfunction of arm control Regeneration valve of arm control valve may have malfunction. valve (regeneration valve) Check it directly. Malfunction or defective seal of arm control valve The relief valve or makeup valve inside the arm control valve may (Relief valve and makeup have malfunction or defective seal. Check the valves directly. valve) ● Stop the engine. Perform troubleshooting while the engine is running at high idle. Cut off the oil passage to the high-pressure side of the cylinder. Failure of arm cylinder

SA

6

NY

Possible causes and standard value in normal state

1

Standard value in normal state/Remarks on troubleshooting

RI C

Cause

Disconnect the cylinder from the main valve. Measure the displacement of piston for 15 minutes after the cylinder becomes stable. If the measured value is greater than 10 mm, it is deemed that cylinder has a defective seal. For more information on the measuring procedure refer to "Testing and Adjusting", "Hydraulic Drift (Work Equipment) - Test".

Shop Manual - June 2013

7-103

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

H-8 Bucket speed slow Trouble

● The bucket moves slowly. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.

Related information

Standard value in normal state/Remarks on troubleshooting

2

Failure of pressure sensor

RI C

AM E

Malfunction of bucket control valve Spool of bucket control valve may have malfunction. Check it directly. (spool) Malfunction or defective seal of Relief valve and makeup valve in bucket control valve may have malbucket control valve function or defective seal. Check the valves directly. (relief valve and makeup valve) ● Stop the engine. Perform troubleshooting while the engine is running at high idle. Charge the bucket with a load of approximate 1260 kg. Cut off the oil passage to the high-pressure side of the cylinder. Disconnect the cylinFailure of bucket der from the main valve. Measure the displacement of piston for 15 mincylinder utes after the cylinder becomes stable. If the measured value is greater than 10 mm, it is deemed that cylinder has a defective seal. For more information on the measuring procedure refer to "Testing and Adjusting", "Hydraulic Drift (Work Equipment) - Test".

LA

4

● Stop the engine. Perform troubleshooting while the engine is running at high idle. Check the pressure sensor by replacing it with a new one.

TI N

3

A

1

● Stop the engine. Perform troubleshooting while the engine is running at high idle. Malfunction of right Bucket control lever Pilot valve output pressure pilot valve (bucket "NEUTRAL" 0 {0} circuit) ≥3.5MPa Bucket CURL or Bucket DUMP {36 kg/cm²}

SA

5

NY

Possible causes and standard value in normal state

Cause

7-104

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

H-9 Work equipment cylinders no response in separate operation ● Boom cylinder gives no response in separate operation. ● Arm cylinder gives no response in separate operation. ● Bucket cylinder gives no response in separate operation.

Trouble

● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting. Standard value in normal state/Remarks on troubleshooting

A

Cause

1

Malfunction of pilot valve

"NEUTRAL"

AM E

DIG or DUMP

RI C

● Stop the engine. Perform troubleshooting while the engine is running at high idle. Work equipment control lever Pilot valve output pressure 0 {0}

≥3.5MPa {36 kg/cm²}

● Stop the engine. Perform troubleshooting while the engine is running at high idle. Check the pressure sensor by replacing it with a new one.

3

Malfunction of control valve (spool)

Spool of control valve may have malfunction. Check it directly.

TI N

2

Failure of pressure sensor

SA

NY

LA

Possible causes and standard value in normal state

Related information

Shop Manual - June 2013

7-105

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

H-10 Work equipment drifts excessively Trouble (1)

● The boom drifts at excessive speed. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.

Related information

Standard value in normal state/Remarks on troubleshooting

3

4

AM E

2

tive seal. For more information on the measuring procedure refer to "Testing and Adjusting", "Hydraulic Drift (Work Equipment) - Test". Failure of boom retain- Boom retaining valve or pilot valve may be worn or sluggish. Check ing valve the valves. Malfunction or defective seal of boom control The relief valve and the makeup valve in the boom control valve valve (relief valve and may have a defective seal. Check the seals. makeup valve)

TI N

1

RI C

A

● Stop the engine. Perform troubleshooting while the engine is running at high idle. Charge the bucket with a load of approximate 1260 kg. Cut off the oil passage to the high-pressure side of the cylinder. Disconnect the Failure of boom cylinder cylinder from the main valve. Measure the displacement of piston for 15 minutes after the cylinder becomes stable. If the measured value is greater than 10 mm, it is deemed that cylinder has a defec-

Failure of boom valve Spool of boom valve may be worn excessively. Check the spool. spool

SA

NY

LA

Possible causes and standard value in normal state

Cause

7-106

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

Trouble (2) Related information

TI N

AM E

Malfunction or defective seal of 2 arm control valve (relief valve and makeup valve) Failure of arm 3 retaining valve Failure of arm 4 Arm valve (spool) may be worn excessively. Check it directly. valve (spool)

Trouble (3)

Related information

1

NY

Cause Failure of bucket cylinder

SA

Possible causes and standard value in normal state

A

Failure of arm cylinder

● Stop the engine. Perform troubleshooting while the engine is running at high idle. Cut off the oil passage to the high-pressure side of the cylinder. Disconnect the cylinder from the main valve. Measure the displacement of piston for 15 minutes after the cylinder becomes stable. If the measured value is greater than 10 mm, it is deemed that cylinder has a defective seal. For more information on the measuring procedure refer to "Testing and Adjusting", "Hydraulic Drift (Work Equipment) - Test". Relief valve or makeup valve of the arm control valve may be defective. Check the valves directly. ● The performance of seal can be judged by replacing it with another relief valve or makeup valve. (Do not replace it with the boom-down relief valve or makeup valve as their pressures are set differently.) Arm retaining valve or pilot valve may be worn or sluggish. Check the valves.

RI C

1

Standard value in normal state/Remarks on troubleshooting

● The bucket drifts excessively. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.

LA

Possible causes and standard value in normal state

Cause

● The arm drifts excessively. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.

Standard value in normal state/Remarks on troubleshooting ● Stop the engine. Perform troubleshooting while the engine is running at high idle. Bucket control lever Leakage from bucket cylinder

Bucket-in relief 20 ml/min Seal of relief valve or makeup valve of bucket control valve may be defecDefective seal tive. Check it directly. of bucket control 2 ● The performance of seal can be judged by replacing it with another valve (relief valve relief valve or makeup valve. (Do not replace it with the boom-down and makeup valve) relief valve or makeup valve as their pressures are set differently.) Defective seal 3 of bucket control Seal of bucket control valve spool may be defective. Check it directly. valve (spool)

Shop Manual - June 2013

7-107

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

H-11 Work equipment moves sluggishly Trouble

● Work equipment moves sluggishly. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.

Cause

Standard value in normal state/Remarks on troubleshooting

Malfunction of arm Regeneration valve of arm may have malfunction. Check it directly. regeneration valve

2

Relief valve or makeup valve of control valve may have malfunction. Malfunction of Check it directly. control valve (relief ● For arm and boom, whether a valve has malfunction can be judged valve and makeup by replacing it with another relief valve or makeup valve. (Do not replace it with the boom-lower relief valve or makeup valve as valve) their pressures are set differently. )

AM E

RI C

A

1

TI N

Possible causes and standard value in normal state

Related information

H-12 Other work equipment moves while single oil circuit is relieved

7-108

Standard value in normal state/Remarks on troubleshooting

NY

Cause

SA

Possible causes and standard value in normal state

Related information

● Other work equipment moves while single oil circuit of certain work equipment is relieved. ● Set the working mode to (S) in order to perform troubleshooting.

LA

Trouble

1

Defective seal of control valve

Seal of control valve may be defective. Check it directly.

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

H-13 Travel speed drops considerably while swinging and travelling Trouble

● Travel speed drops considerably in swinging plus travelling operation. ● If the travel speed is low in only travelling operation, check first according to H-15. Standard value in normal state/Remarks on troubleshooting

Failure of straight travel valve

The straight travel valve gives no response. Check the spool and the logic oil circuit drain port.

AM E

1

RI C

A

Cause

SA

NY

LA

TI N

Possible causes and standard value in normal state

Related information

Shop Manual - June 2013

7-109

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

H-14 Machine deviates during travel Trouble

● Machine deviates during travel. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.

Related information

Malfunction of pilot relief valve

A

2

RI C

Malfunction of travel pilot valve

● Stop the engine. Perform troubleshooting while the engine is running at high idle. Travel control lever Pilot valve output pressure Forward 3.5~3.9 MPa Reverse { 36~40 kg/cm²} Difference occurs between 0.4 MPa {4 kg/cm²} left and right output ● Stop the engine. Perform troubleshooting while the engine is running at high idle. Control lever Control circuit source pressure

AM E

1

All levers in "NEUTRAL"

6

7

TI N

5

Check the regulator by swapping the front and back regulators. ● Stop the engine. Perform troubleshooting while the engine is running at high idle. Sluggishness of proportionTravel control lever Proportional valve output pressure al solenoid valve Operate both control levers ≤0.1 MPa Sluggishness of travel conCheck the valve spool to see whether it works well. trol valve (spool) Internal leakage of central Check it by swapping the lines. swivel joint ● Stop the engine. Perform troubleshooting while the engine is running at high idle. Malfunction of travel motor Travel control lever Leakage of travel motor

LA

4

9

3.5~3.9 MPa { 36~40 kg/cm²}

Failure of regulator

NY

3

8

7-110

Standard value in normal state/Remarks on troubleshooting

Travel relief 27.2 ml/min Final drive may have internal defect. Check it directly. ● Internal defect of the final drive can be determined through Failure of final drive abnormal noise, abnormal heat, and metal powder or debris contained in the oil drained. ● Stop the engine. Perform troubleshooting while the engine is running at high idle. Travel control lever Pilot valve output pressure Failure of travel pilot presForward 3.5~3.9MPa sure sensor Reverse { 36~40 kg/cm²} Difference occurs between 0.4 MPa {4 kg/cm²} left and right output Check the sensor by swapping it with another one.

SA

Possible causes and standard value in normal state

Cause

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

H-15 Travel speed is low Trouble Related information

A

Forward Reverse

3.5~3.9 MPa { 36~40 kg/cm²}

Difference occurs between left and ≤0.4 MPa right output ≤{4 kg/cm²} ● Stop the engine. Perform troubleshooting while the engine is running at high idle. Malfunction of pilot Control lever Control circuit source pressure relief valve 3.5~3.9 MPa All levers in "NEUTRAL" { 36~40 kg/cm²}

AM E

2

Malfunction of travel pilot valve

● Stop the engine. Perform troubleshooting while the engine is running at high idle. Travel control lever Pilot valve output pressure

Failure of sensor

Travel speed

Travel control lever

Reading on monitor

Lo

Operated

3.5~3.9 MPa { 36~40 kg/cm²}

LA

3

TI N

● Stop the engine. Perform troubleshooting while the engine is running at high idle.

4

Operated

Malfunction of travel Spool of travel control valve may have malfunction. Check it directly. control valve (spool) Malfunction of travel The makeup valve in travel control valve may have malfunction. Check control valve (makeit directly. up valve) Stop the engine. Perform troubleshooting while the engine is running at high idle. Failure of travel moTravel control lever Oil leakage of travel motor tor

SA

5

3.5~3.9 MPa { 36~40 kg/cm²} Check the sensor by replacing it with another one.

Hi

NY

Possible causes and standard value in normal state

1

Standard value in normal state/Remarks on troubleshooting

RI C

Cause

● Machine travel speed is low. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.

6

7

Travel relief 27.2 ml/min Final drive may have internal defect. Check it directly. ● Internal defect of the final drive can be determined through abnorFailure of final drive mal noise, abnormal heat, and metal powder or debris contained in the oil drained.

Shop Manual - June 2013

7-111

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

H-16 Machine is not steered well or steering power is low Trouble

● Machine is not steered well or steering power is low ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.

Related information

Cause

3.5~3.9 MPa { 36~40 kg/cm²} ● Stop the engine. Perform troubleshooting while the engine is running at high idle.

4

Both sides operated

3.5~3.9 MPa { 36~40 kg/cm²}

Either side operated

3.5~3.9 MPa { 36~40 kg/cm²}

Spool of travel control valve may have malfunction. Check it directly.

Malfunction of travel The makeup valve in travel control valve may have malfunction. control valve (makeup Check it directly. valve) Seal of relief valve in travel motor may be defective. Check it diFailure of travel motor rectly. (relief valve) ● The failure of seal can be determined by swapping the front and back motors or the left and right motors. Seal of check valve in travel motor may be defective. Check it diFailure of travel motor rectly. (check valve) ● The failure of seal can be determined by swapping the front and back motors or the left and right motors.

SA

6

Malfunction of travel control valve (spool)

Solenoid valve output pressure

TI N

3

Malfunction of travel pilot pressure sensor

Travel control lever

LA

2

AM E

Either side operated

5

7-112

RI C

A

● Stop the engine. Perform troubleshooting while the engine is running at high idle. Travel control lever Pilot valve output pressure Malfunction of travel pilot valve Both sides in "NEUTRAL" 0 {0}

NY

Possible causes and standard value in normal state

1

Standard value in normal state/Remarks on troubleshooting

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

H-17 Travel speed cannot be changed Trouble

Cause

Standard value in normal state/Remarks on troubleshooting

2

AM E

1

RI C

A

● Stop the engine. Perform troubleshooting while the engine is running at high idle. Solenoid valve output Malfunction of travel Travel speed Travel control lever pressure speed shifting solenoid Lo Operated 0 {0} valve 3.5~3.9 MPa Hi Operated { 36~40 kg/cm²} Failure of travel motor (in Speed shifting assembly of travel motor may have malfunction. speed change) Check it directly.

SA

NY

LA

TI N

Possible causes and standard value in normal state

Related information

● Travel speed cannot be changed. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.

Shop Manual - June 2013

7-113

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

H-18 Travel system fails (only at one side) Trouble

● One side of the tracks cannot make a turn. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.

Related information

Cause

Standard value in normal state/Remarks on troubleshooting

RI C

2

Defective seat of travel Seat of relief valve in travel control valve may have malfunction. motor (relief valve) Check it directly.

AM E

Defective seat of travel Seat of check valve in travel motor valve may have malfunction. 3 motor valve (makeup Check it directly. valve) ● Stop the engine. Perform troubleshooting while the engine is running at high idle. Speed of travel motor 4 Travel control lever Leakage from travel motor drops.

Defective pilot pressure sensor

Forward Reverse

Difference occurs between left and right output Check it with swapping method.

SA

NY

6

TI N

5 Failure of final drive

Travel relief 27.2 ml/min Final drive may have internal defect. Check it directly. ● Internal defect of final drive can be determined with abnormal noise, overheat, and metal powder or debris contained in the oil drained. ● Stop the engine. Perform troubleshooting while the engine is running at high idle. Travel control lever Pilot valve output pressure

LA

Possible causes and standard value in normal state

A

Defective seat of travel Seat of makeup valve in travel control valve may have malfunction. 1 control valve (makeup Check it directly. valve)

7-114

Shop Manual - June 2013

3.5~3.9MPa { 36~40 kg/cm²} 0.4 MPa {4 kg/cm²}

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

H-19 Swing operation fails Trouble (1) Related information

Malfunction of swing Parking brake of swing motor may have malfunction. Check it directly. motor (parking brake)

A

1

Standard value in normal state/Remarks on troubleshooting

Swing control lever Swing relief pressure Improper adjustment or malfunction of 25.5~28.5 MPa Swing relief swing motor (relief {260~291 kg/cm²} valve) If oil pressure does not become normal after adjustment, swing motor relief valve may have malfunction or internal defect. Check the relief

AM E

2

RI C

● Stop the engine. Perform troubleshooting while the engine is running at high idle.

4

Failure of swing mechanism

TI N

3

valve directly. ● Stop the engine. Perform troubleshooting while the engine is running at high idle. Failure of swing motor Swing control lever Leakage from swing motor Swing relief ≥10 ml/min Swing mechanism may have internal defect. Check it directly. ● Internal defect of swing mechanism can be determined with abnormal noise, overheat, and metal powder or debris contained in the oil drained.

SA

NY

LA

Possible causes and standard value in normal state

Cause

● Upper structure fails to swing in either direction. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.

Shop Manual - June 2013

7-115

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

Trouble (2)

● Upper structure only fails to swing in one direction. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.

Cause

Standard value in normal state/Remarks on troubleshooting ● Stop the engine. Perform troubleshooting while the engine is running at high idle.

2

Malfunction of swing control valve (spool)

Left control lever

Pilot valve output pressure

"NEUTRAL"

0 {0}

Swing

≥3.5MPa {≥36 kg/cm²}

A

Malfunction of pilot valve

RI C

1

Spool of swing control valve may have malfunction. Check it directly.

AM E

Defective seal of Seal of makeup valve in swing motor may have defect. Check it directly. 3 swing motor (makeup ● Failure of the seal can be determined by swapping the right and left makeup valves and check for any changes. valve)

SA

NY

LA

TI N

Possible causes and standard value in normal state

Related information

7-116

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

H-20 Swing acceleration poor or swing speed low Trouble (1) Related information

Malfunction of swing Parking brake of swing motor may have malfunction. Check it directly. motor (parking brake)

A

1

Standard value in normal state/Remarks on troubleshooting

RI C

AM E

2

● Stop the engine. Perform troubleshooting while the engine is running at high idle. Swing control lever Swing relief valve Improper adjustment or malfunction of 25.5~28.5 MPa Swing relief swing motor (relief {260~291 kg/cm²} valve) If oil pressure does not become normal after adjustment, swing motor

TI N

3

relief valve may have malfunction or internal defect. Check the relief valve directly. ● Stop the engine. Perform troubleshooting while the engine is running at high idle. Failure of swing moSwing control lever Leakage from swing motor tor Swing relief

4

Clogging of brake control lines

≤10 ml/min

Disassemble, clean and check.

SA

NY

LA

Possible causes and standard value in normal state

Cause

● Swing acceleration is poor, or swing speed is low. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.

Shop Manual - June 2013

7-117

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

● Swing acceleration is only poor on one side, or swing speed is low. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.

Trouble (2) Related information

A

Malfunction of pilot valve

● Stop the engine. Perform troubleshooting while the engine is running at high idle. Swing control lever Pilot valve output pressure "NEUTRAL" Left swing Right swing

0 {0}

RI C

1

Standard value in normal state/Remarks on troubleshooting

≥3.5MPa {≥36 kg/cm²}

TI N

AM E

Malfunction of swing Pressure compensation valve of swing motor may have malfunction. 2 motor (pressure comCheck it directly. pensation valve) Seal of makeup valve in swing motor may have defect. Check it diDefective seal of swing rectly. 3 motor (makeup valve) ● Swap the left and right makeup valves and observe the result in order to determine whether the seal fails. ● Stop the engine. Perform troubleshooting while the engine is running at high idle. One-side leakage of Swing control lever Pilot valve output pressure 4 swing pilot pressure "NEUTRAL" 0 {0} sensor (shuttle valve) Left swing 3.5~3.9MPa {36~40 kg/cm²} Right swing

SA

NY

LA

Possible causes and standard value in normal state

Cause

7-118

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

H-21 Upper structure overruns remarkably when it stops swinging ● Upper structure overruns remarkably when it stops swinging in both directions. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.

Trouble (1)

Cause

Standard value in normal state/Remarks on troubleshooting

A

If oil pressure does not become normal after adjustment, swing motor

relief valve may have malfunction or internal defect. Check the relief valve directly. ● Stop the engine. Perform troubleshooting while the engine is running at high idle. Failure of swing motor Control lever Leakage from swing motor Swing relief

NY

Cause

≤10 ml/min

● Swing acceleration is only poor on one side, or swing speed is low. ● Set the working mode at gear (10) of power mode (S) to perform troubleshooting.

LA

Related information

1

25.5~28.5 MPa {260~291 kg/cm²}

AM E

2

Swing relief

RI C

Improper adjustment 1 or malfunction of swing motor (relief valve)

Trouble (2)

Malfunction of pilot valve

Standard value in normal state/Remarks on troubleshooting

● Stop the engine. Perform troubleshooting while the engine is running at high idle. Swing control lever Pilot valve output pressure

"NEUTRAL" 0 {0} Left swing ≥3.5MPa {≥36 kg/cm²} Right swing Malfunction of swing con- Spool of swing control valve may have malfunction. Check it direct2 trol valve (spool) ly. Seal of makeup valve in swing motor may be defective. Check it Malfunction or defecdirectly. 3 tive seal of swing motor ● Swap the left and right makeup valves and observe the result (makeup valve) in order to determine whether the seal fails.

SA

Possible causes and standard value in normal state

● Stop the engine. Perform troubleshooting while the engine is running at high idle. Swing control lever Swing relief pressure

TI N

Possible causes and standard value in normal state

Related information

Shop Manual - June 2013

7-119

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

H-22 Large shock is produced when upper structure stops swinging Trouble

● Large shock is produced when upper structure stops swinging. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.

Cause

Standard value in normal state/Remarks on troubleshooting

2

3

Swing control lever

Pilot valve output pressure

RI C

Malfunction of swing pilot valve

"NEUTRAL"

0 {0}

Left swing ≥3.5MPa {≥36 kg/cm²} Right swing Reverse prevention valve of swing motor may have malfunction. Malfunction of swing Check it directly. reverse prevention ● Replace the valve with a new on in order to determine whether the valve valve fails.

AM E

1

A

● Stop the engine. Perform troubleshooting while the engine is running at high idle.

Malfunction of swing relief valve

Swing relief valve may be worn or sluggish.

TI N

Possible causes and standard value in normal state

Related information

H-23 High noise is produced when upper structure stops swinging

7-120

NY

Cause

Malfunction of back pressure valve Malfunction of swing 2 motor (relief valve)

1

SA

Possible causes and standard value in normal state

Related information

● High noise is produced when upper structure stops swinging. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.

LA

Trouble

Standard value in normal state/Remarks on troubleshooting Back pressure valve may have malfunction. Check it directly. Relief valve of swing motor may have malfunction. Check it directly.

Seal of makeup valve in swing motor may have malfunction. Check it directly. ● Swap the left and right makeup valves and observe the result in order to determine whether the seal fails. The swing mechanism is suspected of an internal failure. Check the inside of the machinery itself. Failure of swing mecha4 ● Internal defect of swing mechanism can be determined with abnism normal noise, overheat, and metal powder or debris contained in the oil drained.

Malfunction of swing 3 motor (makeup valve)

Shop Manual - June 2013

Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator

H-24 Swing drift excessive Trouble (1)

Standard value in normal state/Remarks on troubleshooting

RI C

A

Cause

Failure of swing hold- Swing holding brake control lines and holding brake pilot valve may be ing brake control lines defective. Check them directly.

2

Malfunction of swing Parking brake of swing motor may have malfunction. Check it directly. motor (parking brake)

AM E

1

TI N

Possible causes and standard value in normal state

Related information

● Hydraulic drift of swing is large (when swing holding brake is applied). ● When swing lock switch is turned ON or when swing holding brake release switch is in normal position, swing holding brake operates and upper structure is fixed with disc brake.

● Hydraulic drift of swing is large (when swing holding brake is released). ● When swing holding brake release switch is in release position, swing holding brake is released and upper structure is secured by only hydraulic pressure.

LA

Trouble (2)

NY

Cause Malfunction or defec1 tive seal of swing control valve (spool)

Standard value in normal state/Remarks on troubleshooting Swing control valve spool may have malfunction or defective seal. Check it directly.

SA

Possible causes and standard value in normal state

Related information

2

Failure of swing motor Seal of relief valve in swing motor may be defective. Check it directly. (relief valve)

3

Failure of swing motor Seal of makeup valve in swing motor may be defective. Check it di(makeup valve) rectly.

Shop Manual - June 2013

7-121

SY195/205/215/225C9 Crawler Hydraulic Excavator

BSLAN AYNL AT K IN PAA M GERI E CA

Troubleshooting

7-122

Shop Manual - June 2013

Disassembly and Assembly

A

SY195/205/215/225C9 Crawler Hydraulic Excavator

RI C

Disassembly and Assembly 8 Disassembly and Assembly

SA

NY

LA

TI N

AM E

8.1 How to Read This Manual ....................................................................................... 8-5 8.1.1 Removing and Installing an Assembly ........................................................... 8-5 8.1.2 Disassembling and assembling an assembly ................................................ 8-5 8.1.3 Special tools................................................................................................... 8-5 8.2.1 The symbols used in this section .................................................................. 8-6 8.2 Operating Precautions ............................................................................................. 8-6 8.3 Start Motor AS - Remove and Install ..................................................................... 8-10 8.3.1 Removal ....................................................................................................... 8-10 8.3.2 Installation .................................................................................................... 8-10 8.4 Injection Pump AS - Remove and Install ................................................................8-11 8.4.1 Removal ........................................................................................................8-11 8.4.2 Installation .................................................................................................... 8-13 8.5 Engine Front Seal - Remove and Install ................................................................ 8-15 8.5.1 Removal ....................................................................................................... 8-15 8.5.2 Installation .................................................................................................... 8-15 8.6 Engine Rear Seal - Remove and Install................................................................. 8-16 8.6.1 Removal ....................................................................................................... 8-16 8.6.2 Installation .................................................................................................... 8-17 8.7 Cylinder Head AS - Remove and Install ................................................................ 8-18 8.7.1 Removal ....................................................................................................... 8-18 8.7.2 Installation .................................................................................................... 8-22 8.8 Radiator AS - Remove and Install.......................................................................... 8-24 8.8.1 Removal ....................................................................................................... 8-24 8.8.2 Installation .................................................................................................... 8-27 8.9 Engine and Hydraulic Pump AS - Remove and Install .......................................... 8-28 8.9.1 Removal ....................................................................................................... 8-28 Shop Manual - June 2013

8-1

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

SA

NY

LA

TI N

AM E

RI C

A

8.9.2 Installation .................................................................................................... 8-34 8.10 Final Drive AS - Remove and Install .................................................................... 8-35 8.10.1 Removal ..................................................................................................... 8-35 8.10.2 Installation .................................................................................................. 8-36 8.11 Final Drive AS - Disassemble and Assemble ....................................................... 8-37 8.11.1 Disassembly ............................................................................................... 8-37 8.11.2 Assembly .................................................................................................... 8-41 8.12 Swing Motor and Swing Drive AS - Remove and Install ...................................... 8-46 8.12.1 Removal ..................................................................................................... 8-46 8.12.2 Installation .................................................................................................. 8-47 8.13 Swing Motor and Swing Drive AS - Disassemble and Assemble......................... 8-48 8.13.1 Disassembly............................................................................................... 8-48 8.13.2 Assembly.................................................................................................... 8-53 8.14 Idler AS - Disassemble and Assemble ................................................................. 8-58 8.14.1 Disassembly............................................................................................... 8-58 8.14.2 Assembly.................................................................................................... 8-59 8.15 Sprocket - Remove and Install............................................................................. 8-62 8.15.1 Removal ..................................................................................................... 8-62 8.15.2 Installation .................................................................................................. 8-62 8.16 Track AS - Remove and Install ............................................................................ 8-63 8.16.1 Removal ..................................................................................................... 8-63 8.16.2 Installation .................................................................................................. 8-65 8.17 Swing Bearing AS - Remove and Install .............................................................. 8-66 8.17.1 Removal ..................................................................................................... 8-66 8.17.2 Installation .................................................................................................. 8-67 8.18 Swing Platform AS - Remove and Install ............................................................. 8-68 8.18.1 Removal ..................................................................................................... 8-68 8.18.2 Installation .................................................................................................. 8-71 8.19 Swivel Joint AS - Remove and Install .................................................................. 8-72 8.19.1 Removal ..................................................................................................... 8-72 8.19.2 Installation .................................................................................................. 8-74 8.20 Swivel Joint AS - Disassemble and Assemble ..................................................... 8-75 8.20.1 Disassembly............................................................................................... 8-75 8.20.2 Assembly.................................................................................................... 8-76 8.21 Hydraulic Tank AS - Remove and Install.............................................................. 8-77 8.21.1 Removal ..................................................................................................... 8-77 8.21.2 Installation .................................................................................................. 8-79 8.22 Control Valve AS - Remove and Install ................................................................ 8-80

8-2

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

SA

NY

LA

TI N

AM E

RI C

A

8.22.1 Removal ..................................................................................................... 8-80 8.22.2 Installation .................................................................................................. 8-84 8.23 Hydraulic Pump AS - Remove and Install ............................................................ 8-85 8.23.1 Removal ..................................................................................................... 8-85 8.23.2 Installation .................................................................................................. 8-89 8.24 Middle Oil Seal (Hydraulic Pump Input Shaft)- Remove and Install .................... 8-90 8.24.1 Removal ..................................................................................................... 8-90 8.24.2 Installation .................................................................................................. 8-90 8.25 Pilot Valve AS (Work Equipment) - Disassemble and Assemble ......................... 8-91 8.25.1 Assembly.................................................................................................... 8-91 8.26 Pilot Valve AS (Travel) - Disassemble and Assemble .......................................... 8-93 8.26.1 Assembly.................................................................................................... 8-93 8.27 Hydraulic Cylinder AS - Disassemble and Assemble........................................... 8-94 8.27.1 Disassembly............................................................................................... 8-95 8.27.2 Assembly.................................................................................................. 8-100 8.28 Work Equipment AS - Remove and Install......................................................... 8-105 8.28.1 Removal ................................................................................................... 8-105 8.28.2 Installation ................................................................................................ 8-107 8.29 Air Conditioner AS - Remove and Install............................................................ 8-108 8.29.1 Removal ................................................................................................... 8-108 8.29.2 Installation .................................................................................................8-112 8.30 Counterweight AS - Remove and Install .............................................................8-113 8.30.1 Removal ....................................................................................................8-113 8.30.2 Installation .................................................................................................8-114 8.31 Cab AS - Remove and Install..............................................................................8-115 8.31.1 Removal ....................................................................................................8-115 8.31.2 Installation .................................................................................................8-119 8.32 Cab Window Glass – Disassemble and Assemble ............................................ 8-120 8.32.1 Removal ................................................................................................... 8-121 8.32.2 Installation ................................................................................................ 8-125 8.33 Front Window AS - Disassemble and Assemble................................................ 8-138 8.33.1 Disassemble ............................................................................................ 8-138 8.33.2 Assemble ................................................................................................. 8-141 8.34 Monitor - Remove and Install ............................................................................. 8-146 8.34.1 Removal ................................................................................................... 8-146 8.34.2 Installation ................................................................................................ 8-146 8.35 Controller AS - Remove and Install.................................................................... 8-147 8.35.1 Removal ................................................................................................... 8-147

Shop Manual - June 2013

8-3

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

SA

NY

LA

TI N

AM E

RI C

A

8.35.2 Installation ................................................................................................ 8-147 8.36 Radio ................................................................................................................. 8-148 8.36.1 Structure .................................................................................................. 8-148 8.36.2 Removal ................................................................................................... 8-149 8.36.3 Installation ................................................................................................ 8-150 8.36.4 Connector model and wiring .................................................................... 8-150 8.37 Battery ............................................................................................................... 8-151 8.37.1 Structure .................................................................................................. 8-151 8.37.2 Removal ................................................................................................... 8-152 8.37.3 Installation ................................................................................................ 8-153 8.37.4 Replacement ............................................................................................ 8-153 8.38 Start Switch........................................................................................................ 8-154 8.38.1 Structure ................................................................................................. 8-154 8.38.2 Removal ................................................................................................... 8-155 8.39 Fuse Box............................................................................................................ 8-157 8.39.1 Removal ................................................................................................... 8-157 8.40 Wiper ................................................................................................................. 8-158 8.40.1 Structure .................................................................................................. 8-158 8.40.2 Working principle ..................................................................................... 8-158 8.40.3 Removal ................................................................................................... 8-159 8.40.5 Installation ................................................................................................ 8-160 8.40.4 Angle adjustment of wiper arm................................................................. 8-160 8.41 Relay.................................................................................................................. 8-161 8.41.1 Engine relays ........................................................................................... 8-161 8.41.2 Other relays ............................................................................................. 8-162 8.42 Sensor ............................................................................................................... 8-165 8.43 Connector Terminals - Insert and Remove ........................................................ 8-167 8.43.1 Insertion ................................................................................................... 8-167 8.43.2 Removal ................................................................................................... 8-168

8-4

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8 DISASSEMBLY AND ASSEMBLY 8.1 How to Read This Manual 8.1.1 Removing and Installing an Assembly Removal

RI C

A

● The "Removal" section contains procedure, precautions and the amount of oil or water to be discharged. Installation

AM E

● Unless specified otherwise, installation of a part is a reverse procedure of removing the part.

8.1.2 Disassembling and assembling an assembly Disassembly

TI N

● The "Disassembly" section contains procedure, precautions and the amount of oil or water to be discharged. Assembly

LA

● The "Assembly " section contains operating procedure, precautions, technical specification and the amount of oil or water to be added.

NY

8.1.3 Special tools ● Special tools for parts disassembly and assembly are listed.

SA

● Necessary characteristics of the tools are noted in the list of special tools. ■: Special tools that cannot be replaced and must be used. ●: Very useful tools, which can be replaced with commercially available ones.

Shop Manual - June 2013

8-5

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.1.4 The symbols used in this section This section uses some symbols and icons that are not used elsewhere in this manual. They include: This symbol indicates the amount of oil or water to be discharged. This symbol indicates that specific coating agent must be used. This symbol indicates the lubricant required.

RI C

A

This symbol indicates a torque specified. This symbol indicates the amount of oil or water to be added.

AM E

This symbols indicates the weight of a component or an assembly.

8.2 Operating Precautions

The following precautions must be observed before removing or installing (disassembling or assembling) a component.

TI N

1. Precautions to be observed prior to removal operation ● Dispose the engine coolant properly if antifreeze is contained in the engine coolant.

LA

● After disconnecting a hose or tube, cover or plug must be used to prevent invasion of dirt or dust. ● A suitable container must be prepared to collect oil when draining the oil. ● Matching mark must be made at where is necessary before removing in order to avoid mistake during reinstallation.

NY

● Do not pull the wire and avoid the wire coming off. To avoid excessive force imposing on the wire, hold the connector when disconnecting a wire.

SA

● Tag the wires and the hoses in order to ensure their connecting positions. By doing so, mistakes can be avoided during reinstallation. ● Count and check the number and thickness of the shims, and keep them in a safe place. ● When raising or lifting components, be sure to use proper lifting equipment of ample strength and safety. ● When forcing screws are used to remove any components, tighten the screws evenly in turn. ● The surrounding area must be cleaned before removing a unit. Cover the unit after removal in order to prevent invasion of dirt or dust.

8-6

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

● Precautions to be observed when disassembling the lines The lines disassembled must be blinded with plugs. A: Thread-connected hoses I.D. (mm)

Code

Description

B210780001189

Plug

8

B210780001190

Plug

10

B210780000077

Plug

12

B210780000078

15

B210780000883

20

B210780000079

22

60056667

RI C

6

A

Light Thread Connection

Plug Plug

AM E

Plug

Plug

Heavy Thread Connection B210780001142

16

60002397

20

B210780000080

Plug

25

B210780000081

Plug

TI N

12

Plug Plug

B: Thread-connected adaptors (plug and nut used in combination) Code

Description

LA

I.D. (mm)

Code

Description

Light Thread Connection

B210780000903

Taper bore plug

23002925

Nut

8

B210780001146

Plug

B210770000011

Nut

10

B210780000088

Plug

B210334000011

Nut

B210780000089

Plug

B210334000012

Nut

B210780000882

Plug

B210334000004

Nut

20

B210780000090

Plug

B210334000010

Nut

22

B210780000091

Plug

B210780000112

Nut

12

SA

15

NY

6

Heavy Thread Connection

12

B210780001143

Plug

B210780000406

Nut

16

A820205001523

Plug

B210780000405

Nut

20

B210780000902

Plug

B210780000904

Nut

25

B210780001172

Plug

B210334000006

Nut

Shop Manual - June 2013

8-7

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

2. Precautions prior to installation operation ● Tighten all the screws and nuts (sleeve nuts) to specified torques. ● Install the hoses without twisting or interference. ● Replace the gaskets, O-rings, cotter pins and lock plates with new parts. ● Bend the cotter pin or lock plate securely.

A

● Before applying the adhesive, clean the parts of oil and dust. Apply 2 or 3 drops of adhesive to the threaded portion.

RI C

● Before applying the sealant to the gasket, clean the gasket surface of oil and dust. Check the gasket for contamination or damage. Apply the gasket sealant evenly.

● Apply engine oil to the moving parts.

AM E

● Clean all parts, and correct any damage, dents, burrs, or rust.

● Before installing a snap ring, make sure that the snap ring is mounted properly in the circular groove.

TI N

● Before connecting the wiring connector, clean the wiring connector of oil, dirt or water. Make sure that the wiring connector is connected securely. ● Before using an eyebolt, check the eyebolt for deformation or deterioration. Screw on the eyebolt as far as possible and align it to the direction of the hook.

LA

● Before tightening the split flange, tighten it evenly in turn in order to prevent over tightening on one side.

NY

NOTE: After reassembling the hydraulic cylinder, main pump or other hydraulic equipment that has been disassembled and repaired, it is necessary to bleed the air from the hydraulic cylinder prior to initial operation of the cylinder. The purging procedure is performed as the following: 1) Start the engine and run the engine at low idle.

SA

2) Operate the work equipment control lever in order to cycle the movement of the hydraulic cylinder 4 or 5 times. Hold the cylinder at where it is 100 mm from its stroke end. 3) Go on operating the hydraulic cylinder 3 or 4 times to its stroke end. 4) You can run the engine at normal speed after this operation. NOTE: This procedure is to be performed before using your machine for the first time after repair or long storage.

8-8

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

3. Precautions to be observed upon completion of the operations ● Completely discharge the engine coolant, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system. Check the coolant level again. ● Add hydraulic oil to the specified level after disassembly and reinstallation of a hydraulic unit. Run the engine to circulate the hydraulic oil through the system. Check the oil level again.

RI C

A

● Bleed the air from the system after removing and repairing the lines or hydraulic unit and reassembling the parts. For more information, see “Air in Each Component - Bleed” on page 6-46.

SA

NY

LA

TI N

AM E

● Add the specified amount of grease (molybdenum disulphide) to the work equipment related parts.

Shop Manual - June 2013

8-9

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.3 Start Motor AS - Remove and Install 8.3.1 Removal CAUTION

RI C

A

● Before removing the start motor assembly, disconnect the cable from the negative (-) post of the battery, and insulate between the cable and the negative post with insulation tape.

2. Disconnect the cables (1), (2), (3), (4) and (5).

Starter

Terminal B

TI N

3. Unscrew the bolts (6) and (7) used to fix the start motor. Remove the start motor assembly.

AM E

1. Open the engine hood.

NY

LA

Terminal S

Starter relay ZX215-1006001

8.3.2 Installation

1

2

3

4

6

SA

● Installation is to be performed in the reverse order of removal. Terminal B locknut (start motor): 18 ~ 25 N·m {1.8 ~ 2.6 kgf·m} Fixing bolts (start motor): 43±6 N·m {4.4±0.6 kgf·m}

5 7 ZX215T-1006002

8-10

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.4 Injection Pump AS - Remove and Install 8.4.1 Removal CAUTION

A

● Disconnect the negative (-) post of the battery.

ZX215T-1006003

1

LA

TI N

2. Disconnect the air intake hose (1).

AM E

RI C

1. Open the engine hood.

SA

NY

ZX215T-1006004

3. Disconnect fuel supply tube (2), fuel delivery hose (4), fuel return hose (3) and fuel supply tube (5).

5

● Block the hose with a cork in order to prevent flow of fuel from the hose. 3 2

4

Shop Manual - June 2013

ZX215T-1006005

8-11

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

4. Disconnect the lubrication tube (6).

RI C

A

6

ZX215T-1006006

5. Disconnect six fuel delivery tubes (7).

ZX215T-1006007

LA

TI N

AM E

7

6. Disconnect the air hose (8).

7. Remove the bolt (9) fixing the electronic choke. Disconnect the bolt (10) fixing the governor motor.

SA

NY

8

9

10 ZX215T-1006008

8-12

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8. Adjust the injection timing of the timing gear. For more information, see “Fuel Injection Timing - Test and Adjust” on page 6-13. 9. Remove the injection pump mounting nuts in order to disassemble the injection pump assembly. B

A: 4 nuts on the flange

8.4.2 Installation ● Installation is to be performed in the reverse order of removal.

TI N

Bolts for installation of fuel supply tube:

ZX215-1006009

AM E

RI C

A

A

B: 1 nut

20~29 N·m {2.1~3.0 kgf·m} Relief valve:

LA

20~29 N·m {2.1~3.0 kgf·m} Bolts for installation of engine oil line: 10~13 N·m {1.0~1.3 kgf·m}

NY

Fuel injection tube: 24 N·m {2.5 kgf·m}

SA

Bolts for installation air hose: 12~15 N·m {1.2~1.5 kgf·m}

● Adjust the engine speed. For more information, see “Engine Speed - Test and Calibrate” on page 6-3.

Shop Manual - June 2013

8-13

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

● Installation of the fuel injection pump is to be performed as the following: 1) Check the fuel injection timing to see if it has been adjusted properly. ● For more information, see “Fuel Injection Timing - Test and Adjust” on page 6-13.

Nut: 9.8±2 N·m {10±0.2 kgf·m}

A

● Air bleeding

AM E

LA NY SA 8-14

B

ZX215-1006009

TI N

Bleed the air from the fuel injection system.

RI C

A

2) Assemble the fuel injection pump assembly and tighten the 4 nuts at position A and 1 nut at position B.

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.5 Engine Front Seal - Remove and Install 8.5.1 Removal 1. Remove the radiator assembly. For more information, see “Radiator AS Remove and Install” on page 8-24.

A

Water pump

2. Remove the engine fan (1), the belt (2) and the pulley (3).

3

2 ZX215-1006010

6

Ta 4 7 5

ZX215-1006011

NY

LA

TI N

3. Remove the mounting nut (4) and replace the cone (5) and the O-ring (6). Remove the crankshaft belt pulley (7).

AM E

RI C

1

SA

4. Disassemble the front oil seal (8).

8.5.2 Installation ● Installation is to be performed in the reverse order of removal.

8

Nut: 490 N·m {50 kgf·m}

Shop Manual - June 2013

ZX215-1006012

8-15

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.6 Engine Rear Seal - Remove and Install 8.6.1 Removal 1. Remove the hydraulic pump assembly. For more information, see “Hydraulic Pump AS - Remove and Install” on page 8-85.

3. Remove the flywheel (4). 4. Remove the engine speed sensor (5) and the flywheel shell (6).

3

RI C

A

2. Remove the bolt (1), the latch piece (2) and the bearing (3).

6

Ta 1

4

AM E

2

ZX215-1006013

LA

TI N

5. Remove the rear seal (7).

5

Lip

7

SA

NY

ZX215-1006014

8-16

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.6.2 Installation ● The installation is to be performed in the reverse order of removal. Bolt: 39 N·m {4.0 kgf·m} + 47°

Sealant

1. Apply engine oil to the lips of the rear seal. 2. Clean the oil-sealing surface. 3. Apply the sealant evenly and continuously align the line of the rear seal.

ZX215-1006015

SA

NY

LA

TI N

4. The installation is to be performed 3 minutes after application of the sealant. Be careful not to deviate the line while applying the sealant.

ø2mm

AM E

Sealant (Tonsun 1596)

Line

RI C

A

● The rear oil seal is to be installed according to the following procedure:

Shop Manual - June 2013

8-17

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.7 Cylinder Head AS - Remove and Install 8.7.1 Removal CAUTION

A

● Disconnect the negative (-) post of the battery.

RI C

1. Drain the engine of coolant. Coolant: 18 L

AM E

2. Open the engine hood.

1

LA

TI N

3. Disconnect the air intake hose (1).

ZX215T-1006016

NY

ZX215T-1006017

SA

4. Remove piping (2) and piping (3) between the fuel filter and the injection pump.

3 2 ZX215T-1006018

8-18

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

5. Remove the fuel filter bracket (4) and the fuel filter assembly (5). 6. Remove the six delivery hoses (6).

4

AM E

LA

ZX215T-1006020

8. Remove the air cleaner suction hose (8).

NY

9. Remove the air intake tube (9) and its clamps (10) between the turbocharger and the intercooler.

ZX215T-1006019

6

TI N

7. Remove the exhaust muffler connector cover (7).

RI C

A

5

9 10

7

SA

10. Remove the engine oil delivery tube (11) and the oil return tube (12).

8

Shop Manual - June 2013

ZX215T-1006021

8-19

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

11. Remove the turbocharger assembly.

A

11

RI C

12

ZX215-1006022

AM E

13

TI N

12. Remove the exhaust manifold (13).

LA

ZX215-1006023

14

SA

NY

13. Remove the radiator inlet hose (14) and outlet hose (15).

15 ZX215T-1006024

8-20

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

14. Remove the six nozzle seats (16).

RI C

A

16

16. Remove the rocker arm assembly (18). 17. Remove the pushrod (19).

TI N

18. Remove the 25 mounting bolts from the cylinder head assembly. Lift the cylinder head assembly in order to disassemble it.

AM E

15. Remove the rocker arm housing (17).

17

18

19 20

LA

19. Remove the cylinder head gasket (21).

ZX215T-1006025

SA

NY

21

ZX215-1006026

Shop Manual - June 2013

8-21

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.7.2 Installation ● The installation is to be performed in the reverse order of removal. Installation of cylinder head gasket

A

Choose a cylinder head gasket as per the following.

Unit: mm Cylinder Head Gasket

TI N

Piston Projection

AM E

2. Select from the following table a gasket with a thickness suitable for the maximum piston projection after measurement. In addition, even if one cylinder's piston projection is 0.05 mm greater than the average, the gasket with a thickness one grader higher (A→B, B→C) is to be used.

RI C

1. Measure the amount of piston projection of each cylinder.

Size

0.546~0.610

A

Thickness Tightened 1.3

0.610~0.674

B

1.35

0.674~0.738

C

LA

Average

A

Size mark B

C

1.4

“UP”

NY

3. The size of cylinder head gasket is determined according the notch.

SA

4. Install the cylinder head gasket to the crankshaft case as indicated by the arrow.

Notch

NOTICE

ZX215-1006027

The amount of piston projection must be measured as the amount of piston projection may vary when replacing a piston or connecting rod.

8-22

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

Bolt (rocker cover installation): 4.9~6.9 N·m {0.5~0.7 kgf·m} Bolt (cylinder head): 147 N·m {15 kgf·m}+90° Bolt threads (cylinder head):

A

Engine oil

RI C

Tappet circumference: Engine oil Tappet ends:

● Adjustment of valve clearance F o r m o r e i n f o r m a t i o n , s e e “ Va l v e Clearance - Adjust” on page 6-8.

AM E

Engine oil

TI N

● Adding coolant

SA

NY

LA

Add engine coolant to the specified level. Start the engine to circulate the coolant in order to release all foams. Check the coolant level again.

Shop Manual - June 2013

8-23

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.8 Radiator AS - Remove and Install 8.8.1 Removal 1. Open the engine hood.

A

2. Open the pressure cap (1). Open the drain valve to discharge engine coolant from the coolant tank. Coolant: approx. 18 L

RI C

1 Cover plate

4. Remove the two U-bolts (2).

ZX215T-1006028

TI N

5. Disconnect the hydraulic oil cooler inlet connector (3) and outlet connector (4). Block the openings to prevent leakage of hydraulic oil.

AM E

3. Remove the coverplate.

3

LA

6. Discharge hydraulic oil from the hydraulic cooler. Hydraulic oil radiator: approx. 5.6 L 7. Disconnect the coolant tank hose (5).

4

2

NY

ZX215T-1006029

SA

8. Disconnect the cooler inlet hose (6) and outlet hose (7).

5

ZX215T-1006030

8-24

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

9. Disconnect the intercooler air inlet tube (8) and outlet tube (9).

6

8

RI C

ZX215T-1006031

10

10

TI N

10. Remove the four bolts (10) from the air conditioner radiator. Remove the air conditioner radiator and store it properly.

AM E

7

A

9

LA

ZX215T-1006032

SA

NY

11. Remove the radiator fan guard (11).

11

ZX215T-1006033

Shop Manual - June 2013

8-25

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

12. Remove the four mounting bolts (12) from the radiator bottom and the two mounting bolts (13) from the left and right brackets.

A

13

SA

NY

LA

TI N

NOTE: Before the radiator assembly is hoisted, move the radiator assembly axially until the fan avoids its guard.

8-26

ZX215T-1006034

AM E

13. Mount the hoisting bolts (14) to both sides of the radiator in order to hoist the radiator assembly.

RI C

12

Shop Manual - June 2013

14

ZXT335-1006029

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.8.2 Installation ● Installation is to be performed in the reverse order of removal. NOTE:

A

● Adjust the clearance (a) between the fan and the fan guard in order to have a uniform clearance surrounding the fan.

RI C

● Check the values (a) at the four measuring points in the left, right, top and bottom directions, which should be as the following:

Fan diameter (b): ø620 mm Fan guard inner diameter (c): ø650 mm ● Engine coolant and hydraulic oil adding

AM E

Standard clearance (a) in all directions: 15±1.5 mm

TI N

Add a specific amount of coolant and hydraulic oil. Start the engine to circulate the coolant and hydraulic oil. Check the coolant level and the oil level.

LA

Engine coolant: approx. 18 L

SA

NY

Hydraulic oil radiator: approx. 12 L

Shop Manual - June 2013

8-27

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.9 Engine and Hydraulic Pump AS - Remove and Install 8.9.1 Removal CAUTION

RI C

A

● Lower the work equipment to the ground. Stop the engine. Disconnect the cable from the battery negative (-) post.

NOTE: Mark the lines to avoid mistakes during reinstallation. 1. Remove the hydraulic tank suction filter element and block the opening.

AM E

● Loosen the butterfly nut on the breather valve and press the relief button to relieve internal pressure.

TI N

2. Drain the engine of coolant. Coolant: approx. 18 L

LA

3. Open the engine hood.

NY

ZX215T-1006028

SA

4. Disconnect piping (1), (2) and (3).

2

3

1 ZX215T-1006036

8-28

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

5. Disconnect piping (4), (5) and (6). 5

6. Remove the sensors (7) and (8).

6 4

A

7

AM E

7. Remove the clamps (9) and (10). Remove the line (11) and the cable (12).

RI C

8

ZX215T-1006037

11

10

LA

TI N

9

12

NY

ZX215T-1006038

SA

8. Unscrew the connection bolt (13) of the governor motor and the connection bolt (14) of the engine stopper. 9. Disconnect the external cable from the starter (15). 10. Remove the mounting bolt (16) from the hose clamp.

15 14 13

16 ZX215T-1006039

Shop Manual - June 2013

8-29

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

11. Disconnect the cables (17) and (18) as well as the tubes (19) and (20) from the compressor.

18

20

17

RI C

A

19

12. Disconnect the hoses (21), (22), (23) and (24) between the engine and the radiator

AM E

ZX215T-1006040

24

TI N

21

22 23

LA

ZX215T-1006041

SA

NY

13. Disconnect the air intake hose (25).

25 ZX215T-1006042

8-30

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

14. Disconnect the external cable (26) of the rpm sensor. 15. Disconnect the external cable (27) of engine oil pressure sensor.

27

17. Disconnect the wiring (30) of the engine oil pressure switch.

AM E

16. Disconnect the engine oil inlet tube (28) and outlet tube (29).

RI C

A

26

ZX215T-1006043

30

29

TI N

28

LA

ZX215T-1006044

NY

18. Disconnect the cables (31) and (32), and remove the hose clamp (33).

SA

33

32 31 ZX215T-1006045

Shop Manual - June 2013

8-31

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

19. Remove the hose clamp (35). 20. Disconnect the wiring (34) of the water temperature sensor. 35

RI C

A

34

TI N

21. Disconnect the cables (36) and (37) of the water temperature switch.

AM E

ZX215T-1006046

37

36

LA

ZX215T-1006047

22. Disconnect the oil return hose (38).

38

SA

NY

23. Disconnect the A/C water pipe (39).

39 ZX215T-1006048

8-32

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

24. Disconnect the radiator fan guard (40).

Engine and hydraulic pump AS:

41 41 ZX215T-1006050

SA

NY

LA

TI N

640 kg

ZX215T-1006049

AM E

25. Remove the fixing bolt (41) on each of the four mounting plates of the damper. Lift the engine and main pump assembly.

RI C

A

40

Shop Manual - June 2013

8-33

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.9.2 Installation ● Installation is to be performed in the reverse order of removal. ● Open the radiator tank cover to add coolant. Also add coolant to the coolant reservoir.

A

Engine coolant: approx. 22.5 L.

RI C

● Refill the hydraulic tank with hydraulic oil.

● Start the engine to circulate the coolant in order release the foams, and check the coolant level again.

TI N

● Start the engine to circulate the hydraulic oil in the hydraulic system, and check the oil level again.

AM E

Hydraulic tank: approx. 225 L

● Air bleeding

SA

NY

LA

For more information, see “Air in Each Component - Bleed” on page 6-46.

8-34

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.10 Final Drive AS - Remove and Install 8.10.1 Removal CAUTION

RI C

A

● Lower the work equipment to the ground. Stop the engine. Operate the breather valve to release internal pressure.

For more information, see “Sprocket Remove and Install” on page 8-62.

LA

TI N

2. Remove the motor cover plate (1).

AM E

1. Remove the sprocket.

ZX215-1006051

2

SA

NY

3. Disconnect the four hoses (2) of the travel motor and the corresponding hose connectors.

1

ZX215T-1006052

Shop Manual - June 2013

8-35

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

4. Remove the 30 mounting bolts from the final drive assembly (3), and lift the assembly for disassembling. 3

Final Drive Assembly: 250 kg

NOTICE

RI C

A

● Be careful not to damage the surface of mounting seal installed on the hose base.

ZX215-1006053

8.10.2 Installation ● Installation is to be performed in the reverse order of removal.

AM E

● Never use the threaded holes to lift the cover when lifting the final drive.

TI N

Mounting bolts (final drive assembly):

● Hydraulic oil adding

LA

245~309 N·m {25~31 kgf·m}

● Air bleeding

NY

Add hydraulic oil through the filler opening to the specified level. Start the engine to circulate oil in the hydraulic system, and check the oil level again.

SA

For more information, see “Air in Each Component - Bleed” on page 6-46.

8-36

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.11 Final Drive AS - Disassemble and Assemble 8.11.1 Disassembly 1. Oil draining Open the drain plug to drain the oil from the final drive tank.

A

Final drive tank: approx. 4.7 L

to the



AM E

Remove the bolts. Use eyebolts cover (1).

RI C

2. Cover

TI N

1

LA

3. Spacer

ZX215-1006054

2

SA

NY

Remove the spacer (2).

ZX215-1006055

Shop Manual - June 2013

8-37

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

4. No. 1 planetary carrier assembly 3

A

1) Remove the No.1 planetary carrier assembly (3).

2) Disassembly of No.1 planetary carrier assembly. 3) Remove the screws (4). Remove the coverplate (5) from the planetary carrier assembly (6).

7

TI N

4) Remove the thrust washer (7), gear (8), bearing (9), bearing inner race (10) and a second thrust washer (11).

9

AM E

RI C

ZX215-1006056

LA

5. No.1 sun gear shaft

11

5

4

10

8

6 ZX215-1006057

12

SA

NY

Remove No.1 sun gear shaft (12).

ZX215-1006058

8-38

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

6. Thrust washer

13

14

Remove the thrust washer (13). 7. No.2 sun gear

1) Remove the screws (15). Remove the plate (16) and the planetary gear (17) from the carrier assembly (22).

TI N

2) Remove the bearing inner race (19) and outer race (18). Remove the plate (20).

AM E

8. Disassembly of No.2 planetary carrier assembly

RI C

A

Remove No.2 sun gear (14).

18

19

ZX215-1006059

15 16

17

20

23

21 22

3) Remove the screw (21) to take the planetary carrier assembly (22) and the shim (23) from the body.

LA

ZX215-1006060

9. Hub assembly

NY



SA

1) Use eyebolts to remove the hub assembly (24) from the travel motor.

24

ZX215-1006061

Shop Manual - June 2013

8-39

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

2) Disassemble the hub assembly as the following.

27

26

3) Remove the float seal (25). 4) Remove the bearing (26) and bearing (27) from the hub (28).

A

NOTE: Do not damage the bearing retainer when removing the bearing (26). 25

28

RI C

ZX215-1006062

AM E

5) Remove the float seal (29) from the travel motor.

30

SA

NY

LA

TI N

29

8-40

Shop Manual - June 2013

ZX215-1006063

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.11.2 Assembly NOTE: Clean all the parts. Check that these parts are free from any contamination or damage. Apply some engine oil to the sliding surface prior to installation.

1) Install the bearing 26 and bearing (27) by pressing them onto the hub (28).

A

1. Hub assembly

26

AM E

RI C

2) Install the float seal (25).

27

25

28 ZX215-1006062

TI N

● Remove any oil or dust from the O-ring or O-ring contact surface. Dry the parts before installing the float seal.

LA

● After installing the float seal, check that the angle of the floating seal is within 1 mm.

NY

● Apply a thin layer of engine oil to the sliding surface after the float seal has been installed.

SA

ZX215-1006064

3) Install the float seal (29) to the travel motor (30). ● See the above step 2 for the installation procedure.

29

30 ZX215-1006063

Shop Manual - June 2013

8-41

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

4) Use eyebolts to carefully place the hub assembly (24) onto the travel motor. Tap to press fit the bearing.



RI C

A

24

ZX215-1006061

AM E

2. Calculation of shim thickness 1) Measure the thickness (H) of the raised part of No.2 carrier assembly (22).

22

TI N

H

LA

ZX215-1006065

NY

2) Measurement of raised thickness Apply 3000 Kg load to the bearing and measure the value (H) of the raised part of the bearing.

SA

Load 3000Kg h

● Turn the hub 2-3 times before applying a pushing force. ● Do not use a spray gun to cushion the bearing. ● Do not push or strike the resin retainer. 3) Shim thickness calculation: C=H-h.

8-42

Shop Manual - June 2013

ZX215-1006066

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

4) Place the shims on the body and insert the dowel pin. Press the carrier assembly onto the dowel pin and tighten it with screw (21). Apply locking adhesive to the threads.

Tensiometer

Screw-locking adhesive: (Tonsan 1277)

A

Screw (21):

ZX215-1006067

RI C

539±28 N·m {55±2.9 kgf·m}

Tangential force: Max.294 N {30 kg} Maximum tangential force occurs when the rotating direction begins to change.

AM E

● Use a tensiometer to measure the tangential force of hub to motor rotation.

TI N

3. Assembly of No.2 planetary carrier assembly

LA

1) Assemble the No.2 planetary carrier assembly according to the following procedure.

NOTE: Replace the plates (20) and (16) with new parts.

18

19

15 16

17 20 21

23

22

ZX215-1006060

SA

NY

2) Assemble the bearing (18) and bearing (19) to the gear (17). Assemble the top and bottom plates (16) and (20), and place the gear assembly into the carrier assembly (22). 3) Tighten the screw (15). Screw (15): 539±28 N·m {55±2.9 kgf·m} ● Check the flexibility of gear (17) after assembling the planetary carrier assembly.

Shop Manual - June 2013

8-43

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

4. Thrust washer

13

14

Install the thrust washer (13). 5. No.2 sun gear

RI C

A

Install No.2 sun gear (14).

ZX215-1006059

6. No. 1 sun gear shaft

AM E

12

TI N

Install No.1 sun gear shaft (12).

LA

ZX215-1006058

7. No.1 planetary carrier assembly

NY

1) No. 1 planetary carrier assembly is assembled as the following.

9

7

5

4

10

8

SA

NOTE: Replace the thrust washers (7) and (11) with new parts. 2) Assemble the bearings (9) and (10) onto the gear (8). Assemble the top and bottom thrust washers (7) and (11). Place the gear assembly into the carrier assembly (6).

11

3) Fix the coverplate (5) to the carrier assembly (6) with screw (4).

8-44

Shop Manual - June 2013

6 ZX215-1006057

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

4) Install No.1 planetary carrier assembly (3).

A

3

8. Spacer

2

ZX215-1006055

LA

TI N

AM E

Install the spacer (2).

RI C

ZX215-1006056

9. Cover

NY

Use eyebolts to assemble the cover (1). Use a torque spanner to tighten the bolts. Bolts:

SA

73.4±3.63 N·m {7.5±0.4 kgf·m}

Torque wrench

10. Oil adding

Tighten the drain plug and add engine oil through the filler. ZX215-1006068

Final drive case: approx. 4.7 L ● Check the oil level after the final drive has been successfully installed to the chassis.

Shop Manual - June 2013

8-45

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.12 Swing Motor and Swing Drive AS - Remove and Install 8.12.1 Removal CAUTION

RI C

A

● Lower the work equipment to the ground. Stop the engine. Press the release button of the breather valve to release residual pressure in the hydraulic tank. Place the hydraulic lockout control in the LOCK position.

AM E

Release the residual pressure in the hydraulic circuit. Refer to “Residual Pressure in Hydraulic Circuit - Release” on page 6-40. 1. Disconnect the hoses (1) to (7). ● Between hydraulic tank and swing motor (port DR)

3

TI N

● Between central swivel joint and swing motor (port DR)

● Between swing motor and main valve (port M)

LA

● Between swing motor and main valve (port HA)

5

4

1

2

6

7

ZXT225-1106002

● Between swing motor and main valve (port HB)

NY

● Between swing motor and main valve Px port (port SH)

SA

● Between swing motor and solenoid valve block (port PG)

8 9

2. Remove the 11 fixing bolts (8). 3. Lift the swing motor and swing drive assembly (9) for disassembling. NOTE: Slowly lift the swing motor and swing drive assembly in order to avoid damaging the hoses and other parts. Swing motor and swing drive assembly: 260 kg 8-46

Shop Manual - June 2013

ZXT225-1106003

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.12.2 Installation ● Installation is performed in the reverse order of removal. Mounting bolts (swing motor and swing drive assembly): 490~608 N·m {50~62 kgf·m}

A

● Hydraulic oil adding

SA

NY

LA

TI N

For more information, see “Air in Each Component - Bleed” on page 6-46.

AM E

● Air bleeding

RI C

Add hydraulic oil through the filler opening to the specified level. Start the engine to circulate oil in the hydraulic system, and check the oil level again.

Shop Manual - June 2013

8-47

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.13 Swing Motor and Swing Drive AS - Disassemble and Assemble 8.13.1 Disassembly 1. Draining of oil Open the drain plug to drain the oil from the swing drive.

A

Swing drive: approx. 4.4 L

2) Unscrew the 14 bolts in order to remove the swing motor assembly (1).

3. No.1 sun gear

LA

TI N

Swing motor assembly: 70 kg

1

AM E

1) Place the swing motor and swing drive assembly on a suitable cribbing. Be careful not to damage the drive gear or let it contact the ground.

RI C

2. Swing motor assembly

ZX225-1006077

2

SA

NY

1) Remove No.1 sun gear (2).

ZX215-1006072

8-48

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

4. No.1 planetary carrier assembly

4

3

2) Disassemble the carrier assembly.

6

5

7

8

9

NY

LA

TI N

Cut the rivets on the shaft (8) to remove the shaft (8), and remove in turn the gear (6), bearing (9) and plate (7).

ZX215-1006073

AM E

RI C

A

1) Remove No.1 carrier assembly (3) and the plate (4).

5. Ring gear

ZX215-1006074

10

SA

Unscrew the mounting bolts to remove the ring gear (10).

ZX215-1006075

Shop Manual - June 2013

8-49

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

6. No. 2 sun gear

11

RI C

A

Remove No. 2 sun gear (11).

7. No.2 planetary carrier assembly 1) Remove No.2 carrier assembly (12).

AM E

ZX215-1006076

12

LA

TI N

2) Disassemble No. 2 carrier assembly as per the following procedure.

SA

NY

ZX215-1006077

8-50

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

3) Insert pin (13) and push the shaft (14) out of the carrier assembly (19). 19

NOTE: Pull out the pin (13) after removal of the shaft.

16

15

18 17

4) Remove the thrust washer (16), gear (17) and a second thrust washer (19).

14 13

A

5) Insert the pin (15) to remove the bearing (18) from the shaft. Remove the pin (15).

RI C

ZX215-1006078

8. Snap ring

AM E

20

NY

LA

TI N

Remove the snap ring (20).

ZX215-1006079

9. Disassembly of main shaft Press

21

22

SA

1) Place the shaft housing assembly on a press and push the shaft assembly (21) out of the shaft housing assembly (22).

ZX215-1006080

Shop Manual - June 2013

8-51

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

2) Disassemble the shaft assembly in the following procedure.

Press

Remove the bearing (23) from the shaft (24).

23

RI C

A

24

10. Bearing

AM E

ZX215-1006081

26

27

NY

LA

TI N

Remove the bearing (25) and the oil seal (26) from the housing (27).

SA

25

8-52

Shop Manual - June 2013

ZX215-1006082

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.13.2 Assembly NOTE: Clean all the parts and check for any contamination or damage. Apply engine oil to the sliding surface of the parts.

23

1. Bearing

2. Oil seal Press the oil seal (26) into the housing (27).

AM E

RI C

A

Press the bearing (23) into the housing (27).

27

ZX215-1006083

26

TI N

Oil seal installation surface:

27

LA

Gasket sealant (Loctite 515)

NY

ZX215-1006084

3. Housing assembly

SA

24

1) Position the plate (28) on the shaft (24). 2) Position the housing assembly (22) on the shaft (24). Press in the bearing. 22

28

Shop Manual - June 2013

ZX215-1006085

8-53

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

4. Bearing

22

25

Press in the bearing (25). ● When press fitting the bearing, press the bearing inner race and outer race simultaneously. Never press only the inner race.

RI C

A

● After assembling the bearing, check if the housing rotates freely.

5. No. 2 Planetary carrier assembly 1) Reassemble No. 2 carrier assembly according to the following procedure.

19

TI N

2) Assemble the plate (16) in the carrier assembly (19).

AM E

ZX215-1006086

LA

3) Assemble the gear (17) in the carrier assembly (19). Put the bearing (18) on the shaft (14). Slightly tap the pin (15) into the bore after alignment. Use a rubber hammer to tap the pin. Make sure that the pin (15) must not higher than the bearing (18).

SA

NY

4) Push the shaft assembly into the carrier assembly (19). Be careful not to damage the gear and the plate. Align the pin bore of the shaft with that of the carrier assembly, and install the pin (13). Carefully tap the pin with a rubber hammer during installation. NOTE: Installation of the shaft requires rotating the planetary gear. Be careful not to damage the thrust washer.

8-54

Shop Manual - June 2013

16

15

18 17 14 13

ZX215-1006078

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

6. Assemble in turn the snap ring (20), No.2 carrier assembly and No.2 sun gear (11).

No.2 planetary carrier 11

7. Installation of ring gear

ZX215-1006087

AM E

RI C

A

20

10

c

TI N

Apply sealant on the mating surface indicated by (C) and tighten it with screws. Never get the sealant onto the ring gear (10). Mating surface:

LA

Sealant (Loctite 515)

NY

ZX215-1006088

8. No. 1 planetary carrier assembly

SA

1) No. 1 carrier assembly is assembled as per the following procedure. 2) Install the plate (7) into the carrier assembly (5).

5

6

7

8

9

3) Install the gear (6) onto the plate after installing the bearing (9) into the gear. 4) Press the shaft (8) into the gear (6) and the carrier assembly (5). Rivet one end of the shaft.

ZX215-1006074

● Check if the gear rotates freely.

Shop Manual - June 2013

8-55

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

5) Install No. 1 carrier assembly (3) and the plate (4).

4

RI C

A

3

AM E

ZX215-1006073

2

9. No. 1 sun gear assembly

LA

TI N

Install No. 1 sun gear (2).

SA

NY

ZX215-1006072

8-56

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

10. Installation of swing motor assembly Apply sealant to the contact surfaces of the ring gear and the motor cover, and install the swing motor assembly. Contact surface: Sealant (Loctite 515)

A

Swing motor assembly: 55 kg

RI C

Mounting bolts (swing motor):

11. Lubricant adding

ZX215-1006089

LA

TI N

NOTE: The 14 bolt holes of the swing motor and swing drive assembly are distributed nonuniformly. The mating direction of each hole is fixed, as shown in the illustration on the right. The installation of swing motor requires proper alignment of the bolt holes in order to ensure the installation orientation.

AM E

156±5 N·m {16±0.5 kg}

NY

Screw on the drain plug and add lubricant through the filler to the specified level (the upper mark of oil stick).

SA

Swing drive: approx. 4 L

Shop Manual - June 2013

8-57

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.14 Idler AS - Disassemble and Assemble 8.14.1 Disassembly 7

8

6

13 12

2. Remove the float seals (3) from the support (2) and the idler (4). 3. Remove the O-ring (11). Remove the idler (4) from the shaft (5) and the support assembly (7).

5

RI C

4

3

1

2

ZX215-1006090

6

TI N

4. Remove the float seals (6) on the other side from the idler (4), shaft (5) and support assembly (7).

4

AM E

NOTE: The idler contains 80 ml oil, which should be drained completely before disassembling. Spread a cloth on the floor to prevent smearing the floor with oil.

9 11

10

A

1. Remove the dowel pin (1) and the support (2).

LA

5

6

NY

7

SA

ZX215-1006091

5. Remove the dowel pin (8) in order to remove the support (7) from the shaft (5). 6. Remove the bushings (9) and (10) from the idler (4).

9,10

5 4

7

8 ZX215-1006092

8-58

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.14.2 Assembly 1. Install the bushings (9) and (10) in the idler (4). 9

10

4

AM E

2. Assemble the O-ring. Install the support (7) to the shaft (5) with the dowel pin (8).

RI C

A

4

TI N

9,10

ZX215-1006093

5 4

7

8

LA

ZX215-1006092

NY

3. Install the float seals (6) to the idler (4), shaft (5) and support (7) assembly.

SA

● Float seals

6

Completely remove the grease from the contact surfaces (hatched area in the illustration on the right) of O-ring and float seal before installing the float seal. In addition, care must be taken to keep the contact surface of float seal free from dust.

Shop Manual - June 2013

ZX215-1006094

8-59

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

● After installation of the float seals, check that the sealing inclination should be less than 1 mm and the seal protrusion between 5 and 7 mm.

A

a

4. Install the shaft (5) and support (7) assembly to the idler (4).

SA

NY

LA

TI N

AM E

7

RI C

ZX215-1006095

8-60

Shop Manual - June 2013

5

4

ZX215-1006096

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

5. Install the float seal (3) to the idler (4) and support (2). 4

NOTE: Apply oil to the sliding surface of float seal. Care must be taken to keep the sliding surface from any contaminants or dust.

3 2

A

NOTE: Remove the oil and dust from the contact surfaces of the O-ring and float seal.

3

AM E

RI C

ZX215-1006097

LA

TI N

3

6. Install the O-ring. Install the support (2) with the dowel pin (1).

ZX215-1006098

7

8

6

NY

7. Add oil and screw on the plug.

13 12

10

5

SA

Oil: approx.

9 11

80 ml (No.18 hyperbola gear oil)

3

1

Plug:

205.8±49 N·m {21±5 kgf·m} 4

Shop Manual - June 2013

2

ZX215-1006090

8-61

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.15 Sprocket - Remove and Install 8.15.1 Removal 1. Remove the track assembly. Refer to “Track AS - Remove and Install” on page 8-63.

1



3. Remove the sprocket (1).

TI N

AM E

Sprocket: 58 kg

8.15.2 Installation

LA

● Installation is to be performed in the reverse order of removal. Threads (bolt - sprocket):

NY

Thread sealant (Tonsan 1277) Bolts (sprocket):

SA

339±20 N·m {35±2 kgf·m}

8-62

RI C

A

2. Swing the work equipment 90°and lift the chassis with the work equipment. Place a block between the track frame and the track shoe.

Shop Manual - June 2013

ZX215-1006099

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.16 Track AS - Remove and Install Special tools Part Name

Necessity Qty

M

Manual/electric hydraulic track removing/installing machine



1

A

Mark

WARNING

1

TI N

2. Lower the work equipment. Loosen the grease fitting (1) and release the track tension.

AM E

1. Choose a place that has enough space to spread the track. Park the machine when the master pin is between the idler and the carrier roller.

RI C

8.16.1 Removal

● The adjustment cylinder is under extremely high pressure. Never loosen the grease fitting by more than one turn.

LA

ZX215T-1006100

3. Pull out the master pin (2) with the tool (M).

SA

NY

2

M

ZX215-1006101

Shop Manual - June 2013

8-63

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

4. Remove the tool (M). Move the machine forward so that the temporary pin is in front of the idler. Place the block . 5. Remove the temporary pin and the dust seal. Move the machine backward to spread the track (3).



A

3

RI C



SA

NY

LA

TI N

AM E

ZX215-1006102

8-64

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.16.2 Installation ● Installation is to be performed in the reverse order of removal.

Corner

For more information, see “Track Tension Test and Adjust” on page 6-24.

R Corner

Track shoe bolts:

AM E

RI C

Seat surface in close contact

ZX215-1006103

TI N

2. Tighten the bolts of track shoe to the torque below.

Corner

R

1. Bring the R side of the track shoe nut (1) to the link seat surface. Both seat surfaces should be in close contact when assembling the track shoe.

R

A

● Installation procedure of track shoe bolts and nuts

NOTE: If the track shoe bolts are installed from the other side, the corner of nut will interfere with the link seat surface, causing the nut to raise and the bolt to loosen.

Track shoe nut (Square)

LA

750±30 N·m {77±3 kgf·m}

● Use the tool (M) to press the master pin. Make sure that the protrusion of master pin meets the size (a).

NY

Master pin protrusion (a): 2.5±1 mm

SA

● Before installing the dust seal, apply grease (No.2 lithium base) to its contact surface with the bushing.

a

ZX215-1006104

Shop Manual - June 2013

8-65

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.17 Swing Bearing AS - Remove and Install 8.17.1 Removal 1. Remove the swing platform assembly. For more information, see “Swing Platform AS - Remove and Install” on page 8-68.

AM E

RI C

A

2. Dismount the 36 bolts (1) to remove the swing bearing assembly.

2

1

TI N

3.

ZX215T-1006105

Hoist the swing bearing assembly (2).

2

SA

NY

LA

Swing bearing assembly: 314 kg

8-66

ZX215T-1006106

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.17.2 Installation ● Installation is to be performed in the reverse order of removal. Threads (bolt - swing bearing): Thread adhesive (Tonsun 1277) Mounting bolts (swing bearing):

RI C

A

Step 1: Use a pneumatic spanner to tighten the bolts.

Torque to: 549±59 N·m {56±6kgf·m} 1) When a torque spanner is used to tighten the bolts, tighten first the four corners and mark them.

AM E

Step 2:

TI N

2) Other bolts will be tightened clockwise or counterclockwise. After one bolt is tightened, tighten the next one on the diagonal position and make a mark.

LA

3) Tighten the rest bolts in this way.

NY

● Let the S mark in the soft zone of the inner race of the inner ring face the right side, as shown in the photo, and install the swing bearing to the track frame.

SA

● Apply grease to the inside of the gear ring of the swing bearing. NOTE: All gear teeth must be covered by grease . Inner race soft zone

Swing bearing: Grease(supramoly lithium base):15 L

ZX215T-1006107

Shop Manual - June 2013

8-67

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.18 Swing Platform AS - Remove and Install 8.18.1 Removal CAUTION

RI C

A

● Fully extend the arm and the bucket. Lower the work equipment to the ground and move the hydraulic lockout control lever to the LOCK position.

For more information, see “Work Equipment AS - Remove and Install” on page 8-105. 2. Remove the counterweight assembly.

TI N

For more information, see “Counterweight AS - Remove and Install” on page 8-113.

AM E

1. Disassemble the work equipment assembly.

3. Remove the four hoses (1) of boom cylinder.

1

ZX215T-1006108

LA

NOTE: Plug the hoses to prevent flow of oil.

SA

NY

4. Lift the boom cylinder assembly (2).

2 ZX215T-1006109

8-68

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

5. Remove the plate (3) and the pin (4). Lift the boom cylinder assembly (2) in order to remove it.

4

● Remove the boom cylinder assembly on the other side in the same way. Boom cylinder AS: 230 kg

ZX215T-1006110

5 6

TI N

NOTE: Removal of the swing platform requires removing other parts that interfere with the lifting of swing platform.

AM E

6. Remove the plate (5), air intake hose (6) and fan guard (7).

RI C

A

3

7 ZX215T-1006111

LA

7. Disconnect the six hoses above the swivel joint assembly.

NY

● Central swivel joint (port A) - Left travel control valve (port BTL)

SA

● Central swivel joint (port C) - Left travel control valve (port ATL) ● Central swivel joint (port F) - Solenoid valve ● Central swivel joint (port G) - Swing motor (port T) ● Central swivel joint (port D) - Right travel control valve (port ATR)

10 9 8

11 12 13 14

ZX215T-1006112

● Central swivel joint (port B) - Right travel control valve (port BTR) 8. Remove the bolt (14).

Shop Manual - June 2013

8-69

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

9. Unscrew the 32 swing platform mounting bolts in order to remove the swing platform assembly (15). Lift the swing platform assembly off the machine.

15

RI C

A

NOTE: Remove the front and rear mounting bolts of the platform. Use a lever block to adjust the swing platform so that the platform can reach a balance both longitudinally and laterally. Remove the last two bolts finally.

NOTICE

Swing platform assembly:

ZX215T-1006113

AM E

● Be careful not to impact the central swivel joint while removing the swing platform assembly.

Swing Platform Only (Ref.) 1,689 kg

TI N

Assembly

SA

NY

LA

8,427 kg

8-70

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.18.2 Installation ● Installation is to be performed in the reverse order of removal. Clamping screws (air intake hose): 5.4~6.4 N·m {0.55~0.65 kgf·m}

A

Mating surface (swing bearing):

RI C

Flat surface sealant (Tonsun 1596) Threads (bolt - swing platform):

Mounting bolts (swing platform): Step 1: Tighten the bolts with a pneumatic spanner. Step 2: tighten them again.

AM E

Thread adhesive: (Tonsun 1277)

TI N

490~608 N·m {50~62 kgf·m}

● Hydraulic oil adding

LA

Add through the filler opening the hydraulic oil to the specified level. Start the engine to circulate oil in the hydraulic system, and check the oil level again.

NY

● Air bleeding

SA

Bleed the air from the travel motor. For more information, see “Air in Each Component - Bleed” on page 6-46.

Shop Manual - June 2013

8-71

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.19 Swivel Joint AS - Remove and Install 8.19.1 Removal WARNING

A

● Release residual pressure in the hydraulic circuit before disconnecting the hydraulic hoses.

RI C

Refer to “Residual Pressure in Hydraulic Circuit - Release” on page 6-40.

1. Disconnect the six hoses from (1) to (6) on the central swivel joint of the travel motor.

TI N

1) Central swivel joint (port T) - Left travel motor (port T)

AM E

NOTE: Tag each line so as to ensure correction installation.

2) Central swivel joint (port T) - Right travel motor (port T)

4

5

6

LA

3) Central swivel joint (port B) - Left travel motor (port PA) 4) Central swivel joint (port D) - Right travel motor (port PB)

NY

5) Central swivel joint (port A) - Left travel motor (port PB)

SA

6) Central swivel joint (port C) - Right travel motor (port PA)

8-72

3

Shop Manual - June 2013

2 1

ZX215T-1006114

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

2. Disconnect the eight hoses from (7) to (14). 10

7) Central swivel joint (port F) - Left travel motor (port P)

9 13

8) Central swivel joint (port F) - Right travel motor (port P) 7 11

10) Central swivel joint (port F) - Solenoid valve

12

14

RI C

15

13) Central swivel joint (port D) - Right travel control valve (port ATR)

3. Remove the fixing bolt (15).

TI N

14) Central swivel joint (port B) - Right travel control valve (port BTR)

ZX215T-1006115

AM E

11) Central swivel joint (port C) - Left travel control valve (port ATL) 12) Central swivel joint (port A) - Left travel control valve (port BTL)

8

A

9) Central swivel joint (port G) - Swing motor (port T)

LA

4. Remove the four mounting bolts (16).

16 ZX215T-1006116

NY

5. Remove the six mounting bolts (17) from the transition plate. Remove the swivel joint assembly (18). 18

SA

Central swivel joint: 56 kg

Transition plate

17

Shop Manual - June 2013

16 ZX215-1006117

8-73

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.19.2 Installation ● Installation is to be performed in the reverse order of removal. NOTE: Install the central swivel joint facing the direction indicated in the illustration.

BD

Central swivel joint Sprocket

Add through the filler opening the hydraulic oil to the specified level. Start the engine to circulate oil in the hydraulic system, and check the oil level again.

Bleed the air from the travel motor.

SA

NY

LA

TI N

For more information, see “Air in Each Component - Bleed” on page 6-46.

AM E

● Air bleeding

AC

8-74

RI C

A

● Oil adding (hydraulic tank)

Shop Manual - June 2013

ZX215-1006118

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.20 Swivel Joint AS - Disassemble and Assemble 8.20.1 Disassembly 1. Remove the bolt (1) and the spring washer (2).

1 2

2. Remove the cover (3).

3

3. Remove the gasket (4), O-ring (5) and snap ring (6).

A

4

RI C

5

4. Remove the rotor (13) from the housing (9).

5. Remove the spacer (7) and the gasket (8) from the housing (9). 6. Remove the dust seal (12) from the swing shaft (13).

AM E

NOTE: Be careful not to damage the sliding surface of the seal of the rotor (13).

NY

LA

TI N

7. Remove the O-ring seal (11) and the seals (10) from the housing (9).

6 7 8

9

10

11 12

13

SA

ZX215-1006119

ZX215-1006120

Shop Manual - June 2013

8-75

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.20.2 Assembly 1. Install the dust seal (12) on the rotor (13). NOTE: Let the lip face the housing while installing the dust seal.

Dust seal

2. Install the six seals (10) in the housing (9). Lip

4. Use a rubber hammer to tap the housing (9) in order to match the rotor (13) properly.

RI C

ZX215-1006121

TI N

5. Install the spacer (7) and gasket (8) in the housing (9).

Body

AM E

NOTE: Since the clearance between the housing (9) and the rotor (13) is approximately 0.1 mm, install the housing (9) on the rotor (13) slowly and vertically. Be careful not to damage the seals (10) and the O-ring seal (11).

A

3. Fix the rotor (13) on a work bench. Install the housing (9) on the rotor (13).

6. Install the gasket (4), O-ring seal (5) and snap ring (6) on the rotor (13).

LA

7. Install the cover (3). Tighten the bolts (1) and the spring washer (2).

SA

NY

Fixing bolts: 49 N·m{5 kgf·m}

8-76

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.21 Hydraulic Tank AS - Remove and Install 8.21.1 Removal 1. Drain the hydraulic oil into a suitable container for storage or disposal.

1

Hydraulic oil: approx. 225 L

2

5

3

RI C

3. Remove the engine hood (1), cover (2) and control valve cover (3).

ZX215T-1006122

6

7

TI N

AM E

4. Remove the cover mounting frame (4) and the screen (5).

5. Remove the screen (6) and the partition frame mounting bolt (7) on the hydraulic tank side.

4

A

2. Open the engine hood.

LA

6. Remove the screw (8) and the fuel control motor (9).

9

8

NY

ZX215T-1006123

SA

7. Remove the two oil return hoses (10) from the hydraulic tank. 10

ZX215T-1006124

Shop Manual - June 2013

8-77

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8. Disconnect the seven hoses. ● (11): Oil return - pilot T block ● (12): Oil return - main pump 17

● (13): Oil return D2 - main valve ● (14): Sensor - temperature

18

● (16): Oil return D1/D3 - main valve

13 16

● (17): Oil return - swing motor

● Disconnect the oil inlet hose (18) from the hydraulic tank after disconnection of the oil inlet tube from the pump. ● Attach each hose with an identification tag.

14

ZX215T-1006125

19

LA

9. Remove the hose clamp (19).

TI N

● Use a sleeve nut to prevent the fitting and the cone seal from damage.

12

AM E

NOTE:

11

A

15

RI C

● (15): Oil return - solenoid valve

ZXT225-1106008

NY

10. Lift the hydraulic tank assembly and remove the six bolts (20).

SA

11. Lift off the hydraulic tank assembly for disassembling.

20

Hydraulic tank assembly: 130 kg

ZX215T-1006127

8-78

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.21.2 Installation ● Installation is to be performed in the reverse order of removal.

Screw

Drain plug (hydraulic tank): 58.8~78.5 N·m {6.0~8.0 kgf·m} NOTE: After tightening the hose clamping screw, check that the screw should be in the range indicated in the illustration.

RI C

A

Up Down

Screw (hose clamp):

● Install the hose clamp and tighten the screw according to the illustration on the right. Bolt:

● Oil adding (hydraulic tank)

Pipe

TI N

245.2~308.9 N·m {25~31.5 kgf·m}

AM E

8.8±0.5 N·m {0.9±0.05 kgf·m}

LA

Add hydraulic oil through the filler opening to the specified level. Start the engine to circulate oil in the hydraulic system, and check the oil level again.

Clamp

ZX215-1006128

Hose

Bulge ZX215-1006129

NY

● Air bleeding

SA

For more information, see “Air in Each Component - Bleed” on page 6-46.

Shop Manual - June 2013

8-79

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.22 Control Valve AS - Remove and Install 8.22.1 Removal

● Lower the work equipment to the ground. Stop the engine. Press the release button of the breather valve to release residual pressure in the hydraulic tank. Place the hydraulic lockout control in the LOCK position.

RI C

1

AM E

NOTE: Tag each line so as to ensure correction installation.

1. Lift the hood (1).

A

WARNING

2

ZXT225-1106009

TI N

2. Remove the cover (2) above the control valve.

LA

3. Remove the engine silencing hood (3).

3

NY

ZXT225-1106010

SA

4. Remove the baffle (4) to (9) of the pressure transducer and tag them. (4): XAK Bucket DIG (5): XBb1 Boom DOWN

4

(6): XAtL Travel LEFT

5

7 8

(7): XBa1 Arm IN

6

9

(8): XBs Swing RIGHT (9): XAtr Travel RIGHT

8-80

ZXT225-1106011

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

5. Disconnect the pilot hoses (10) to (18) and tag them properly.

10

11

12

13

14

(10): XBtr Travel RIGHT (11): XAs Swing LEFT 18

(12): PSP Swing priority 15

16

(14): XBp2 Bucket confluence

17

RI C

(15): XBtL Travel LEFT

A

(13): XAa1 Arm OUT

(16): XAb1 Boom UP

(18): XAa2 Arm OUT

21 19

20

ZXT225-1106013

NY

LA

TI N

6. Remove the port (19) (accumulator to solenoid valve), port (10) (pilot filter to accumulator). Remove hose clip (21) of the central swivel joint.

AM E

(17): XBK Bucket DIG

ZXT225-1106012

SA

7. Remove bucket hoses (22) and (23) and seal the ports. 8. Remove arm hoses (24) and (25) and seal the ports. 9. Remove boom hoses (26) and (27) and seal the ports.

22

24

25

23

26 27

Shop Manual - June 2013

ZXT225-1106014

8-81

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

10. Remove central swivel joint hoses (28), (29), (30) and (31). Remove travel speed switching hose (32) and seal the ports.

32

31

A

28

30

29

AM E

11. Remove swing motor hoses (33) and (34). Remove swing motor oil complement hose (35). Seal the ports properly.

RI C

ZXT225-1106015

33

34

ZXT225-1106016

LA

TI N

35

12. Remove pipe (36) (main valve to radiator).

SA

NY

36

ZXT225-1106017

8-82

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

13. Remove pipe (37) (main valve to return oil tank). Seal the ports properly.

AM E

ZXT225-1106018

38

39 ZXT225-1106019

LA

TI N

14. Remove hydraulic pump hoses (38) and (39).

RI C

A

37

15. Remove hoses (40) to (44) on the solenoid valve and tag them properly.

NY

(40): PPC lockout valve

SA

(41): Main valve PnA2

(42): Main valve XBP2 (43): Main valve PSP (44): Travel PT port

40 41

42

43

44 WXT215-1208001G

Shop Manual - June 2013

8-83

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

16. Remove the fixing bolts (45). Lift the control valve assembly (46) for disassembling. Control valve assembly: 220 kg

45

45

RI C

A

46

8.22.2 Installation

● Oil adding (hydraulic tank)

TI N

● Installation is to be performed in the reverse order of removal.

AM E

ZXT225-1106021

LA

Add hydraulic oil through the filler opening to the specified level. Start the engine to circulate oil in the hydraulic system, and check the oil level again. ● Air bleeding

NY

Bleed the air from the circuit between the valve and the hydraulic cylinder.

SA

For more information, see “Air in Each Component - Bleed” on page 6-46.

8-84

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.23 Hydraulic Pump AS - Remove and Install 8.23.1 Removal WARNING

RI C

A

● Lower the work equipment to the ground and stop the engine. Press the release button of the breather valve to release residual pressure in the hydraulic tank.

NOTE: Tag each line so as to ensure correction installation.

TI N

1. Remove the oil inlet filter element from the hydraulic tank and stop oil outflow with an oil stopper.

AM E

● Disconnect the cable from the negative (-) post of the battery before performing the job.

NOTE: If no oil stopper is used, remove the drain plug and drain the oil from the hydraulic tank and from circuits.

LA

Oil stopper

Hydraulic tank: Approx. 225 L

ZX215-1006144

SA

NY

2. Lift the hood (1).

1

ZX215T-1006145

Shop Manual - June 2013

8-85

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

A

3. Remove the pin (2) and the bolts (3). Lift the engine hood in order to remove it.

ZX215T-1006146

4

3

LA

TI N

AM E

4. Remove the right upper cover (4).

RI C

2

ZX215T-1006147

SA

NY

5. Disconnect the hose (5) supplying oil to the lower proportional valve and the hose (6) delivering oil from the pilot pump.

5

6 ZX215T-1006148

8-86

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

RI C

7

A

6. Disconnect the shutdown wire (7).

TI N

8. Remove the hydraulic pump cover (9).

AM E

7. Remove the right door (8).

ZX215T-1006149

8 9

LA

ZX215T-1006150

9. Disconnect the oil drain hose (10) and seal the openings properly.

NY

10

SA

10. Disconnect the high-pressure hoses (11) and (12) connecting to the control valve, and seal the openings properly. 11. Disconnect the harness (13) of the pressure transducer. 12. Disconnect the pilot pump oil inlet hose (14) and seal the openings properly.

12 11 13

14

13. Disconnect the pilot pump oil inlet tube (15) and seal the openings properly.

Shop Manual - June 2013

15

ZX215T-1006151

8-87

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

16

18

RI C

A

14. Disconnect the solenoid valve harnesses (16) and (17). Remove the cable straps (18) and (19).

19

17

15. Remove the four bolts (20) of the hydraulic pump. Lift the hydraulic pump assembly (21) to remove it.

21

SA

NY

LA

TI N

Hydraulic pump assembly: 112 kg

AM E

ZX215T-1006152

8-88

Shop Manual - June 2013

20

ZX215T-1006153

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.23.2 Installation ● Installation is to be performed in the reverse order of removal.

Screw

NOTE: After tightening the hose clamping screw, check that the screw should be in the range indicated in the illustration. Up Down

A

Screw (hose clamp):

Mating surface (hydraulic pump housing):

AM E

● Install the hose clamp and tighten the screw according to the illustration on the right.

RI C

8.8±0.5 N·m {0.9±0.05 kgf·m}

Pipe

Clamp

ZX215-1006128

Hose

Bulge ZX215-1006129

LA

TI N

Gasket sealant: (Loctite 515)

● Oil adding (hydraulic tank)

NY

Add hydraulic oil through the filler opening to the specified level. Start the engine to circulate oil in the hydraulic system, and check the oil level again.

SA

Hydraulic tank: approx. 225 L ● Air bleeding

For more information, see “Air in Each Component - Bleed” on page 6-46.

Shop Manual - June 2013

8-89

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.24 Middle Oil Seal (Hydraulic Pump Input Shaft)- Remove and Install 8.24.1 Removal 1. Remove the hydraulic pump assembly (1). For more information, see “Hydraulic Pump AS - Remove and Install” on page 8-85.

1 2

2. Remove the screw (2). Remove the bearing cover (3).

RI C

A

3 4

3. Pry the oil seal (4) out with a screwdriver.

AM E

NOTE: Be careful not to damage the shaft while prying the oil seal.

TI N

8.24.2 Installation

ZX215-1006154

● Installation is to be performed in the reverse order of removal.

4

LA

Seal lip:

Grease (No.1 Calcium base grease) Seal circumference:

NY

Grease (No.1 Calcium base grease)

SA

● Apply a thin layer of grease to the oil seal circumference.

8-90

ZX215-1006155

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.25 Pilot Valve AS (Work Equipment) - Disassemble and Assemble NOTE: This section discusses only the precautions when reassembling the work equipment pilot valve assembly. 8 2

3

4

5

6

7

10

8.25.1 Assembly ● Reassembly of the work equipment pilot valve assembly

TI N

1. Install the plate (9) in the valve body (8) with O-ring seal. Tighten the socket bolt (10).

LA

Socket bolt:

ZX215T-1006156

AM E

RI C

A

1

9

25~33 N·m {2.55~3.36 kgf·m}

Grease (No.1 Calcium base grease) U-joint moving surface: Grease (No.1 Calcium base grease) Threads in valve body: Thread adhesive (Tonsun 1277)

NY

2. Insert the spring (7) into the spool hole in the valve body (8). Put the spool (6) in the spring. Install the plunger (5) on the spool. Push the plug (5) to the spool hole.

Plug (5) circumference:

SA

3. Install the plate (4) on the plunger (5). Tighten the U-joint (3). 4. Install the plate (2). Align the position of the plate (2) and tighten the nut (1). Nut: 98~133 N·m {10~13.5 kgf·m} NOTE: Location of each oil port is stamped on the bottom of valve body.

Shop Manual - June 2013

8-91

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

● A p p l y t h e t h r e a d a d h e s i v e ( To n sun 1277) to two points on the inner threads. The amount of application is approximately 0.02 g.

5~7 mm

U-joint (3): 98~133 N·m {10~13.5 kgf·m}

A

NOTE: Tightening is to be made to the specified torque. Contact surface between plunger (5) and plate (2):

RI C

ZX215-1006157

SA

NY

LA

TI N

AM E

Grease 0.3~0.8 ml (No.1 Calcium base grease)

8-92

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.26 Pilot Valve AS (Travel) - Disassemble and Assemble NOTE: This section discusses only the precautions when reassembling the travel pilot valve assembly.

9

8

7

6

AM E

RI C

A

Plunger

4

3

2

1

5

TI N

ZX215T-1006158

8.26.1 Assembly

LA

● Reassembly of the pedal pilot valve assembly

1. Install the spring (8) into the spool installation hole in the body assembly (9). Install the spool (7). Place the cover assembly (6) on the spool and press the cover assembly (6) with a hand. 2. Install the cover (4) after aligning the holes. Tighten the socket bolts (1).

NY

Bolt (socket): 98~114 N·m {10~11.6 kgf·m}

SA

3. Install the dust ring (3) on the plunger. Install the cover (2) and fix the cover (2) with the camshaft (5). Contact surface between plunger and dust ring (5): Grease (No.1 Calcium base grease)

Shop Manual - June 2013

8-93

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.27 Hydraulic Cylinder AS - Disassemble and Assemble Special tools Application

Tool Shape

Necessity

Quantity



1

RI C

A

Pulling out/pushing in the bushing

TI N

O-ring seal correction

SA

NY

Inserting the piston

8-94

1



1



1



1

Correcting tool

LA

Inserting tool

Inserting the cylinder head



AM E

Press fitting the dust ring

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.27.1 Disassembly 1. Drain the oil and remove the tubing. 2. Fix the cylinder.

A

● Fix the cylinder in a vertical or level manner. A vertically fixed cylinder can be disassembled and assembled easily.

AM E

● Remove the tubing in case of tubing interference while fixing the cylinder.

RI C

● The pin bore in the head end can be used for fixing of the cylinder. The pin roll can prevent the cylinder from turning.

LA

TI N

Fix the cylinder

NY

ZX215-1006164

3. Removal of cylinder head

SA

Approx 1.5m

● Unscrew the bolts with Allen Wrench. ● Using an extension rod, as shown in the illustration on the right, will make the work easy.

ZX215-1006165

Shop Manual - June 2013

8-95

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

4. Pulling out the piston rod ● Be sure to have removed the tubing cover. ● Prepare a suitable container to collect oil coming out of the oil port.

1

● After pulling out the piston rod to its limit, slowly loosen the cylinder head and pull it out.

2

Fixing

5

SA

NY

LA

TI N

● Use pin bore on the rod end or the flat part of the ear to prevent turning of the piston rod.

ZX215-1006166

AM E

5. Fixing the piston rod

RI C

● Remove the piston rod (1) with the cylinder head (2) and place them on a wooden sleeper.

A

Sleeper

8-96

Shop Manual - June 2013

ZX215-1006167

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

6. Remove of the piston nut (5) Drill bit

1) Remove the fixing screw (3) from the piston nut (5).

3

A

NOTE: Around the fixing screw there are two points that have been punched against loosening. After removing the riveted part with a hand drill, loosen and remove the fixing screw (3). 2) Remove the steel ball (4).

RI C

4

3) Remove the piston nut (5).

5

AM E

NOTE: The piston nut (5) is very tight. To loosen the piston nut (5), prepare a hydraulic jack or a spanner powered by hydraulic cylinder. An extension rod should be ready when removing the piston nut (5) manually.

ZX215-1006168

TI N

Hydraulic jack Hydraulic cylinder

LA

ZX215-1006169

7. Removal of piston assembly

2

6

7

SA

NY

● Remove in turn the piston (7), buffer sleeve (6) and cylinder head (2).

ZX215-1006170

Shop Manual - June 2013

8-97

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8. Removal of the buffer sleeve (8) on the bottom end

Thread

1) Remove first the piston nut (5). Piston rod

9

3) Slide the buffer sleeve (8) toward the piston threads in order to remove the two-piece stopper ring.

RI C AM E

TI N

9. Removal of piston seal 1) The slide ring (12) and the guard ring (13) can be simply removed with hands.

LA

2) The seal (14) can be removed with a hammer and a flat-head screwdriver.

11 (2 pcs)

ZX215-1006171

4) Remove the buffer sleeve (8). 5) There is an opening in the buffer seal (10). Take advantage of this opening to remove the buffer seal (10).

8

10 one gap

A

2) Use a tool like rubber hammer to tap the piston nut (5) slightly for removal while keeping the piston rod and the buffer sleeve (8) intact. Remove the elastic ring (9).

Screwdriver 12

14 Piston

Bench clamp

3) Remove the O-ring seal (15) with a pry bar.

NY

15

13

ZX215-1006172

SA

NOTE: The removed seals should not be reused.

10. Removal of buffer ring (16) NOTE: The buffer ring (16) is installed in the inner groove in the cylinder head. Use a tool with sharp end to pry it out and remove it with a scraper.

18

17

16

19

20

ZX215-1006173

8-98

Shop Manual - June 2013

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

11. Removal of the U-ring (17) and the dust ring (18) Press

1) Remove the U-ring (17) with a tool such as screwdriver. Cushion

2) Pierce a tool (such as a screwdriver) into the dust ring (18) and hammer the screwdriver to remove the dust ring (18). NOTE: The removed seals should not be reused.

RI C

Support

2) Push the bushing (19) out with the help of clamps and press. 13. Removal of bushing (21)

ZX215-1006174

AM E

12. Removal of bushing (19) 1) Remove the elastic ring (20) from the cylinder head (2) with a screwdriver.

A

21

TI N

1) Remove the dust ring (22) on the side of cylinder barrel and piston rod with a tool such as screwdriver.

SA

NY

LA

2) Remove the bushing (21) with the help of a suitable cushion block.

Shop Manual - June 2013

8-99

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.27.2 Assembly 1. Installation of bushing (21) 1) Use a mounting tool to press the bushing (21) into the bushing (lubricated with hydraulic oil) on the side of piston rod and cylinder barrel.

Press Mounting tool 21

2) Install the dust ring (22) with the help of a suitable cushion block.

Cushion

Piston rod

21

RI C

A

22

2. Assembly of cylinder head (2) 1) Use the press to push in the bushing (19).

Hydraulic press

2

Tool

TI N

NOTE: Apply hydraulic oil to the inside of cylinder head in advance. Make sure that the bushing (19) pushed in is free from a raised shoulder.

AM E

ZX215-1006175

19

Pressure surface

LA

2) Use the press to push in dust ring (18).

ZX215-1006176

Tool

SA

NOTE:

NY

3) Install the guard ring and the U-ring (17) sequentially in the U-groove.

● Install the U-ring (17) in correct direction. Make sure that the U-ring is intact before installation.

18 U-groove

Press in

● Inverse installation will cause leak of oil. ● Make sure that the U-ring is free from any corrugation or permanent deformation after installation.

8-100

Shop Manual - June 2013

ZX215-1006177

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

4) Installation of buffer ring (16) NOTE: Make sure that the seal is installed in correct direction. Inverse installation can cause high pressure between the buffer ring (16) and the U-ring (17), which may lead to deformation or breakage of oil cylinder.

A

5) Install the elastic ring (20) to prevent the fall of the bushing (19).

RI C

3. Assembling the piston assembly 1) Installation of seal (14).

2) Correction of seal (14)

AM E

18

17

20

19

Press Block

Press

Tool 13

NY

LA

NOTE: Install the seal (14) and the guard ring (13) on the other side. In order to prevent the expansion of the seal (14), a corrector must be used to correct the seal (14) which has been stretched during installation. The piston rod may not be able to go in the cylinder barrel if the seal (14) is not corrected timely.

16

ZX215-1006173

TI N

NOTE: Install first the O-ring seal and the one-side guard ring (13) on the piston. Place the piston on the press. As shown in the illustration on the right, the seal (14) is installed with the tools indicated.

Tool

3) Installation of slide ring (12)

Corrector

Piston

SA

NOTE: Slightly open the slide ring (12) and install it axially. Excessive opening of the slide ring (12) can fail installation.

12 14 13

O-ring

ZX215-1006179

Shop Manual - June 2013

8-101

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

4. Assembling the piston rod assembly 1) Fix the piston rod (1).

2

Assembly tool

2) Install the cylinder (2) on the piston rod. NOTE: Make sure that the dust ring lip or the U-ring lip is not stopped by the shoulder of any part. Install the cylinder head and the piston rod with the tools.

RI C

TI N

5) Install the buffer sleeve (8) according to the indication in the illustration on the right.

ZX215-1006180

AM E

4) Let the notched side of the buffer seal (10) face the piston while installing the buffer seal (10) in the groove.

A

1

3) If the bottom side of cylinder contains a buffer (not for bucket cylinder), install the buffer bearing and the buffer seal in the following order.

Gap facing thread direction Thread

6) Install the stopper ring in the groove. Install the elastic ring after the buffer sleeve (8) is pushed to the bottom. A rubber hammer should be used for the tapping job in order to avoid damaging the piston rod and the buffer bearing.

LA

Piston rod

9

SA

NY

7) If the head side of cylinder contains a buffer, install the buffer sleeve (6) and the buffer seal (23) according to the following order. 8) The piston nut must be installed after installation of the buffer bearing. 9) The buffer seal (23) must be installed in the groove, with its notches facing the piston.

8-102

Shop Manual - June 2013

10 One gap

8 Head end buffer

11 (2 pcs) ZX215-1006181

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

10) The buffer sleeve (6) must be installed according to the illustration on the right.

6

23

5

11) Tighten the piston nut (5). Piston nut (arm): 9600 N·m {979.6 kgf·m} Piston nut (boom and bucket):

A

6200 N·m {632.6 kgf·m}

Gap facing piston side

NOTE:

TI N

● Thoroughly clean and grease (with banana oil) the threaded portions of the piston, nuts and piston rod before tightening the nuts.

ZX215-1006182

AM E

● Insufficient tightening can cause oil leakage, loose nut and thread breakage. In addition, excessive tightening can cause expansion of the buffer shaft on the extending side or deformation of piston on the contact side.

RI C

Rod end buffer

LA

12) Treatment of the piston against loosening

NY

NOTE: After the piston nut (5) is tightened, put in the steel ball (4), tighten the setscrew (3) and punch to rivet the two peripheral points.

Rivet

Punch

Setscrew (3):

SA

66.9 N·m {6.8 kgf·m}

3 4

ZX215-1006183

Shop Manual - June 2013

8-103

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

5. Install the piston into the cylinder barrel

Tool Nylon sleeve (2 pcs type)

1) Fix the barrel in a vertical or level manner. 2) Install the piston rod into the cylinder barrel.

(Spread the gaps by 180°)

NOTE:

RI C

A

● If fixed in a vertical manner, the piston rod falls into the barrel under its gravity.

ZX215-1006184

AM E

● Make sure that the slide ring does not fall while the piston is inserted into the barrel.

TI N

6. Tightening of cylinder head Tighten the cylinder head according to the sequence shown in the illustration on the right.

4

5

6

11 10

3 2

7 Tightening sequence

SA 8-104

9

12

NY

7. Install the tubing.

LA

Bolt: 267 N·m {27.2 kgf·m}

1

8

Shop Manual - June 2013

ZX215-1006185

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.28 Work Equipment AS - Remove and Install 8.28.1 Removal WARNING

RI C

A

● Fully extend the arm and the bucket. Lower the work equipment to the ground. Move the hydraulic lockout control to the LOCK position.

See “Residual Pressure in Hydraulic Circuit Release” on page 6-40.

AM E

● Release residual pressure in the hydraulic circuit.

5

1

1. Disconnect the grease hose (1).

TI N

2. Lift the boom cylinder assembly (2). Remove the lock bolt (3).

3

2

4

3. Remove the plate (4) and then the pin (5).

NOTE: There are shims installed. Count the shims and check the thickness. Place the shims in a safe place.

LA

ZX215T-1006186

4. Start the engine and retract the piston rod.

SA

NY

NOTE: Secure the piston rod with a wire rope in order to prevent the piston from slipping out. Put the cylinder on a bench or support. Remove the grease fitting on the bottom side in the later case. Remove the other boom cylinder in the same way.

5. Remove the two hoses (6) of bucket cylinder and the those (7) of the arm cylinder.

6

8

NOTE: Cork the hoses to prevent outflow of oil. Secure the hoses to the valve side.

10

9

7

ZXT225-1106028

6. Remove the inter-connector (8) used for work lamp.

Shop Manual - June 2013

8-105

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

7. Lift the work equipment and remove the plate (9). Remove the pin (10) from the bottom. NOTE: There are shims installed. Count the shims and mark their locations.

SA

NY

LA

TI N

Work equipment assembly: 3451 kg

11

AM E

8. Lift and disassemble the work equipment assembly.

8-106

ZX215T-1006188

RI C

9

A

10

Shop Manual - June 2013

ZX215T-1006189

Disassembly and Assembly

SY195/205/215/225C9 Crawler Hydraulic Excavator

8.28.2 Installation CAUTION ● Do not put your finger in the pin bore while aligning the pin bore.

A

● Installation is to be performed in the reverse order of removal.

RI C

NOTE: A clearance (a: 0.5~1.5 mm) shall be left between the plate and the nut when tightening the locknut.

Grease (supramoly lithium base)

AM E

Greasing after assembling the pin:

a

TI N

NOTE: Adjust the shim thickness in order to have a desired clearance (a: 0.5
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